Dodge - Stratus Coupe - Workshop Manual - 2003 - 2003

Factory Workshop Manual Make Dodge Model Stratus Coupe Engine and year L4-2.4L VIN G (2003) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Horn Relay > Component Information > Locations Alarm Horn Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Overall View View G Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Overall View View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 18 Radiator Cooling Fan Control Module: Testing and Inspection FAN CONTROLLER CHECK 1. Remove condenser fan motor connector. 2. Start the engine and run it at idle. 3. Turn the A/C switch to ON and maintain the coolant temperature at 80 °C (176 °F) or less. 4. When measuring the voltage between the fan control module-side connector terminals, check that the value changes repeatedly as indicated by (1) - (3) below. (1) 0 Volts (2) 8.2 ± 2.6 Volts (3) Battery positive voltage ± 2.6 Volts 5 If the voltage does not repeatedly change as indicated, replace the radiator fan motor and the fan control module assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 32 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 33 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 34 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 35 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 36 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 37 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 38 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 39 Blower Motor Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 40 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 41 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 42 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 43 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 44 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 45 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 46 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 47 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 48 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 49 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 50 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 51 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 52 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Page 53 Blower Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 57 A/C Compressor Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection Fan Control Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Control Module HVAC: Locations Overall View View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 66 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 71 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 72 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 73 Control Module HVAC: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 74 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 75 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 76 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 78 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 79 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 80 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 81 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 82 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 83 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 84 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 85 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 86 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 91 Fog Light Relay Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 95 Horn Relay, Theft-Alarm Horn Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction Relay Box: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 101 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 102 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 103 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 104 Relay Box: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 105 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 106 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Box: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 109 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 110 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 111 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 112 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 113 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 114 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 115 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 116 Relay Box: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 117 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 118 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 119 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 120 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 121 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 122 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 123 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 124 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 125 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 126 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 127 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 128 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 129 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 130 Relay Box: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 131 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction Relay Box: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 134 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 135 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 136 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 137 Relay Box: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 138 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 139 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 146 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 147 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 148 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding Engine Control Module: Locations Grounding Grounding Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding > Page 151 Engine Control Module: Locations ECM/PCM Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Terminal Voltage Check Chart - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 154 Terminal Voltage Check Chart - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 155 Terminal Voltage Check Chart - Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 156 Terminal Voltage Check Chart - Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 157 Terminal Voltage Check Chart - Part 5 TERMINAL VOLTAGE CHECK CHART Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 161 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 166 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay Continuity Check FUEL PUMP RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 170 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 176 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 178 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 180 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 181 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 182 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 183 Ignition Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 184 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 185 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 186 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 187 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 188 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 189 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 190 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 193 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 194 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 195 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 196 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check Ignition Control Module: Testing and Inspection Analyser Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method Standard Wave Pattern 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 199 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 200 Ignition Control Module: Testing and Inspection Oscilloscope Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 201 Connect the oscilloscope probe to ECM terminal No.10 (for number 1 number 4), terminal No.23 (for number 2 - number 3) respectively. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Overall View View H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 208 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 210 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 211 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 212 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 213 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 214 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Air Bag Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 216 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 217 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 218 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 219 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 220 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 221 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 222 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 223 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 224 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 225 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 226 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 227 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 228 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 229 Air Bag Control Module: Testing and Inspection FRONT SEATBACK ASSEMBLY WITH SIDE-AIRBAG MODULE CHECK WARNING: - If any improper part is found during the following inspection, replace the front seatback assembly with a new one. Dispose of the old one according to the specified procedure. - Never attempt to measure the circuit resistance of the side-airbag module (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental side-airbag deployment will result in serious personal injury. 1. Check the side-airbag module deployment section for dents or deformation. 2. Check the connector for damage, the terminals for deformation, and the harness for binds. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 230 Air Bag Control Module: Service and Repair Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 231 >>A<< SRS-ECU INSTALLATION WARNING: The SRS may not activate if the SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle's driver or front passenger. >>B< Check the head mark "E" on the bolt and attach the grounding bolt. >>C<< POST-INSTALLATION INSPECTION 1. Reconnect the negative (-) battery cable. 2. Turn the ignition switch to the "ON" position. 3. Does the "SRS" warning light illuminate for approximately seven seconds, and then go out? 4. If yes, the SRS system is functioning properly. If no. INSPECTION WARNING: If a dent, crack, deformation or rust is discovered, replace the SRS-ECU with a new one. - Check the SRS-ECU and brackets for dents, cracks or deformation. - Check the SRS-ECU connector for damage, and the terminals for deformation. NOTE: Refer inspection of SRS-ECU for other than physical damage. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions Starter Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 238 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 239 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 240 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 241 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 242 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 243 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 244 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Starter Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 246 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 247 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 248 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 249 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 250 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 251 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 252 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 253 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 254 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 255 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 256 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 257 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 258 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Page 259 Starter Relay: Service and Repair Starter Relay Check STARTER RELAY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 272 Power Window Relay: Description and Operation POWER WINDOW RELAY CONTROL OPERATION Power Window Relay Operation If the ignition switch is turned to "ON" position, the power window relay is energized to activate the power windows. Power Window Timer Function When the ignition switch is turned from the "ON" position to "LOCK" (OFF) or "ACC" position, the power windows can be operated for 30 seconds. If any door is opened for the 30 seconds, the power windows will be immobilized at that point. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 273 Power Window Relay Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 279 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 284 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 285 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Windshield Washer Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 287 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 288 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 289 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 290 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 291 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 292 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 293 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 294 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 295 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 296 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 297 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 298 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 299 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 309 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 310 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 311 Wiper Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 312 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 313 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 314 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 315 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 316 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 317 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 318 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 319 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 320 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 321 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 322 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 323 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 324 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 329 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 330 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 331 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 332 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 334 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 335 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 336 Wiper Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 337 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 338 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 339 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 341 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 342 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 343 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 344 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 345 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 346 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 347 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 348 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 349 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Key Cylinder Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Remote Controlled Mirror Switch Continuity Check Power Mirror Switch: Testing and Inspection Remote Controlled Mirror Switch Continuity Check Remote Controlled Mirror Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Remote Controlled Mirror Switch Continuity Check > Page 362 Power Mirror Switch: Testing and Inspection Remote Controlled Mirror Switch Illumination Check Remote Controlled Mirror Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection BRAKE FLUID LEVEL SENSOR CHECK The brake fluid level sensor is in good condition if there is no continuity when the float surface is above "A" and if there is continuity when the float surface is below "A." Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Testing and Inspection Parking Brake Release Switch: Testing and Inspection PARKING BRAKE, SWITCH CHECK 1. Remove the floor console. 2. Check for continuity between the parking brake switch terminal and the switch mounting bolt. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Wheel speed sensor internal resistance .................................................................................................................................................... 1.28 - 1.92 k Ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 377 Wheel Speed Sensor: Mechanical Specifications Distance between wheel speed sensor installation surface and ABS rotor tooth top; 28.2 - 28.5 mm (1.11 - 1.12 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 378 Wheel Speed Sensor: Locations View c Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 379 View d Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 380 Wheel Speed Sensor: Testing and Inspection WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT Required Special Tool ^ MB991219: Inspection Harness 1. Lift up the vehicle, and release the parking brake. 2. Disconnect the ABS DECO connector A-02, and then use special tool MB991219 to measure the output voltage at the harness side connector. 3. Manually turn the wheel to be measured 112 to 1 burnt second. Measure the output voltage with a voltmeter or oscilloscope. Output voltage: ^ Minimal voltmeter reading: 42 mV ^ Maximum voltmeter reading: 300 mV ^ Minimal oscilloscope reading: 120 mV ^ Maximum oscilloscope reading: 600 mV Probable causes of low output voltage ^ Wheel speed sensor pole piece-to-ABS rotor clearance too large ^ Faulty wheel speed sensor NOTE: Check the connection of the sensor harness and connector before using the oscilloscope. 4. To observe the waveform with an oscilloscope: ^ Front Wheels: Shift into low gear and drive the wheels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 381 ^ Rear Wheels: Turn the wheels manually at a constant speed NOTE: The output waveform is low when the wheel speed is low. Similarly, it will be higher as the wheel speed increases. Waveform may also be observed by driving the vehicle. POINTS IN WAVEFORM MEASUREMENT NOTE: The wheel speed sensor cable moves in relation to motion of the front or rear suspension. Therefore, it is likely that it has an open circuit only when driving on rough roads but it functions normally when driving on smooth roads. It is recommended to observe sensor output voltage waveform also under special conditions, such as driving on a rough road. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 382 Wheel Speed Sensor: Service and Repair REMOVAL AND-INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 383 The clearance between the wheel speed sensor and the ABS rotor's toothed surface is not adjustable, but measure the distance between the sensor installation surface and the ABS rotor's toothed surface. Standard value: 28.2 - 28.5 mm (1.11 - 1.12 inches) INSPECTION SPEED SENSOR CHECK 1. Check whether any metallic foreign material has adhered to the projection at the speed sensor tip. Remove any foreign material. Also check whether the pole piece is damaged. Replace it with a new one if it is damaged. NOTE: The projection can become magnetized due to the magnet inside the speed sensor, causing foreign material to easily adhere to it. The projection may not be able to correctly sense the wheel rotation speed if foreign matter is on it or if it is damaged. 2. Measure the resistance between the speed sensor terminals. Standard value: 1.28 - 1.92 k Ohms 3. If the internal resistance of the speed sensor is not within the standard value' replace it with a new speed sensor. 4. Remove all connections from the speed sensor. The circuit should be open between terminals (1) and (2) and the body of the speed sensor. If the circuit is not open, replace with a new speed sensor. 5 Check the speed sensor cable for breakage, damage or disconnection. Replace with a new one if a problem is found NOTE: When checking for cable damage, remove the cable clamp part from the body and then gently bend and pull the cable near the clamp. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 384 TOOTHED ABS ROTOR CHECK Check whether the ABS rotor teeth are broken or deformed. Replace the driveshaft assembly for the front side or the ABS rotor for the rear side, respectively, if the teeth are damaged or deformed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications Engine Coolant Temperature (ECT) Sensor: Electrical Specifications ITEM .................................................................................................................................................... ............................................ STANDARD VALUE Engine coolant temperature sensor resistance kOhm -20 °C (-4 °F) ............................................................................................................................ .................................................................................. 14 - 17 0 °C (32 °F) .......................................... .............................................................................................................................................................. ..... 5.1 - 6.5 20 °C (86 °F) ................................................................................................................... ......................................................................................... 2.1 - 2.7 40 °C (104 °F) ............................. .............................................................................................................................................................. ............... 0.9 - 1.3 60 °C (140 °F) ....................................................................................................... ............................................................................................... 0.48 - 0.68 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications > Page 391 Sealants And Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 392 Engine Coolant Temperature (ECT) Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 393 Engine Coolant Temperature (ECT) Sensor: Testing and Inspection ENGINE COOLANT TEMPERATURE SENSOR CHECK CAUTION: Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Drain engine coolant, then remove the engine coolant temperature sensor. 2. With the temperature sensing portion of engine coolant temperature sensor immersed in hot water, check the resistance. Standard value: 14 - 17 kOhm @ -20 °C (-4 °F) 5.1 - 6.5 kOhm @ 0 °C (32 °F) 2.1 - 2.7 kOhm @ 20 °C (68 °F) 0.9 - 1.3 kOhm @ 40 °C (104 °F) 0.48 - 0.68 kOhm @ 60 °C (140 °F) 0.26 - 0.36 kOhm @ 80 °C (176 °F) 3. If resistance deviates from the standard value greatly, replace the sensor. 4. Apply 3M AAD part number 8731 or equivalent to threaded portion. 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 ± 10 Nm (22 ± ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 394 Engine Coolant Temperature (ECT) Sensor: Service and Repair SEALANTS AND ADHESIVES ITEM .................................................................................................. .......................................................................................... SPECIFIED SEALANT Engine coolant temperature sensor threaded portion ....................................................................................................................................... MOPAR® Part No. 4318031or equivalent Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection 1. Drain the engine coolant. (Refer to Maintenance Service- Engine Coolant.) 2. Remove the engine coolant temperature gauge unit. 3. Immerse the unit in water of 70 °C (158 °F) to measure the resistance. Standard value: 104 ± 13.5 ohms Reference Value 4. If within the standard value, the sensor is OK. Reinstall it, then check the engine coolant temperature gauge. If not within the standard value, replace it. 5. After checking, apply the MOPAR(R) Part No.4318034 or equivalent around the threads of the engine coolant temperature gauge unit. 6. Add engine coolant. (Refer to Maintenance Service Engine Coolant.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure switch .............................................................................................................................. .......................................... 19 ± 3 Nm (14 ± 2ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil pressure switch .............................................................................................................................. ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection > Page 409 Air Conditioning Switch: Service and Repair Heater Control Assembly And A/C Switch - Removal And Installation REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection > Page 410 Insert a flat-tipped screwdriver into the control base clip from inner side, and then remove the cable by lifting the claw part of the clip. INSTALLATION SERVICE POINT >>A<< HEATER CONTROL ASSEMBLY INSTALLATION 1. Follow the steps below to install the air outlet changeover damper link cable. 1. Set the air outlet changeover control knob on the heater control assembly to the defroster position. 2. Set the air outlet changeover damper link of the heater/ cooler unit to the defroster position as shown in the illustration, and then connect the cable to the link pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 2. Follow the steps below to install the air mix damper lever cable. 1. Set the temperature control knob on the heater control assembly to the maximum hot position. 2. Set the air mix damper lever of the heater/cooler unit to the maximum hot position as shown in the illustration, and then connect the cable to the lever pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 3. After installation, ensure that each damper operates smoothly by operating the heater control assembly knob. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations View J Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions Ambient Temperature Sensor / Switch HVAC: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 416 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 417 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 418 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 419 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 421 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 422 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Ambient Temperature Sensor / Switch HVAC: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 424 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 425 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 426 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 428 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 429 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 430 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 431 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 432 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 433 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 434 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 435 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 436 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Compressor Speed Sensor, HVAC > Component Information > Testing and Inspection Compressor Speed Sensor: Testing and Inspection Revolution Pick-up Sensor Check Measure the resistance between terminals 1 and 3. Check that the measured value is at the standard value. Standard value: 405 ± 35 Ohm when the ambient temperature is 20 °C (68 °F) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations View X Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Overall View Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions Refrigerant Pressure Sensor / Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 451 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 452 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 453 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 454 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 455 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 456 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 457 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 458 Refrigerant Pressure Sensor / Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 459 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 460 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 461 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 462 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 463 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 464 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 465 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 466 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 467 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 468 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 469 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 470 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 471 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 472 Refrigerant Pressure Sensor / Switch: Testing and Inspection PRESSURE SWITCH CHECK 1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the harness side as shown in the illustration. 2. Install a gauge manifold to the high-pressure side service valve of the refrigerant line. 3. When the high/low pressure sides of the dual pressure switch are at operation pressure (ON) and there is continuity between the respective terminals, then the condition is normal. If there is no continuity, replace the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Locations Refrigerant Temperature Sensor: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Locations > Page 476 Refrigerant Temperature Sensor: Testing and Inspection Refrigerant Temperature Switch Check When the A/C is off, check that there is continuity between the refrigerant-temperature switch terminals. If not, replace the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 485 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 486 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 487 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 488 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 489 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 490 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 491 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 492 Dimmer Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 493 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 494 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 495 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 497 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 498 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 499 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 500 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 501 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 502 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 503 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 504 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 505 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 506 Dimmer Switch: Testing and Inspection RHEOSTAT CHECK 1. Connect the battery and the test bulb (40W) as shown in the illumination. 2. Operate the rheostat, and if brightness changes smoothly without switching off, rheostat function is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 507 Rheostat - Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 512 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 513 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 514 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 516 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 517 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 518 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 519 Fuel Gauge Sender: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 520 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 521 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 522 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 523 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 524 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 525 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 526 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 527 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 528 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 529 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 530 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 531 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 532 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Check FUEL GAUGE UNIT CHECK Remove the fuel pump module and the remove the fuel gauge unit. (Refer to Fuel Tank.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 535 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Resistance FUEL GAUGE UNIT RESISTANCE 1. Check that resistance value between the fuel gauge terminal and ground terminal is at the standard value when the fuel gauge unit float is between point Standard value: Point F: 3-5 ohms - Point E: 110 - 112 ohms 2. Check that resistance value changes smoothly when the float moves slowly between point 3. If no problems are found in steps above, go to Fuel gauge unit float height check. If any problem is found, replace the fuel gauge unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 536 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Float Height FUEL GAUGE UNIT FLOAT HEIGHT 1. Move the float and measure height A at point Standard value: A: 180.3 mm (7.10 inches) - B: 18.8 mm (0.14 inch) 2. Adjust the float arm to the standard value, then go to Thermistor check. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 541 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 542 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 543 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 544 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 545 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 546 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 547 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 548 Key Reminder Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 549 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 550 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 551 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 552 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 553 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 554 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 555 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 556 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 557 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 558 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 559 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 560 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 561 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 562 Key Reminder Switch: Electrical Diagrams Forgotten Key Prevention Function Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 563 Forgotten Key Prevention Function Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 564 Forgotten Key Prevention Function Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 565 Forgotten Key Prevention Function Part 4 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Page 566 Key Reminder Switch: Testing and Inspection Disconnect key reminder switch connector without removing the ignition switch and steering lock cylinder. Key reminder switch check Check for continuity between terminal 4 and terminal 6. Ignition key ring antenna check Check for continuity between terminal 3 and terminal 7. Standard value: Should be less than 2 ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 572 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 573 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 574 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 575 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 576 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 577 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 578 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 579 Backup Lamp Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 580 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 581 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 582 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 584 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 585 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 586 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 587 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 588 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 589 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 590 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 591 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 592 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 597 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 598 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 599 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 600 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 601 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 602 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 603 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 604 Brake Light Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 605 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 606 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 607 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 608 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 609 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 610 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 611 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 612 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 613 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 614 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 615 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 616 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 617 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 618 Brake Light Switch: Testing and Inspection STOPLIGHT SWITCH CHECK 1. Connect an ohmmeter between the stoplight switch connector terminals. 2. There should be no continuity between the terminals when the plunger is pushed in as shown. There should be continuity when it is released. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation Fog/Driving Lamp Switch: Description and Operation FOG LIGHT The fog light switch becomes active only when the headlights are at the low-beam mode. Therefore, if the headlights are turned off, the fog lights will also be switched off. When the headlights are turned on during the next key cycle, the fog lights will be off regardless of the fog light switch position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Page 625 Fog Light Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Hazard Warning Light Switch Continuity Check Hazard Warning Light Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Hazard Warning Light Switch Continuity Check > Page 630 Hazard Warning Switch: Testing and Inspection Hazard Warning Light Switch Diagnosis The hazard warning lights are controlled by the Simplified Wiring System (SWS). For troubleshooting, refer to, SWS Diagnosis. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 631 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection Turn Signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 640 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 641 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 645 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 646 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 647 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 648 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications Engine Coolant Temperature (ECT) Sensor: Electrical Specifications ITEM .................................................................................................................................................... ............................................ STANDARD VALUE Engine coolant temperature sensor resistance kOhm -20 °C (-4 °F) ............................................................................................................................ .................................................................................. 14 - 17 0 °C (32 °F) .......................................... .............................................................................................................................................................. ..... 5.1 - 6.5 20 °C (86 °F) ................................................................................................................... ......................................................................................... 2.1 - 2.7 40 °C (104 °F) ............................. .............................................................................................................................................................. ............... 0.9 - 1.3 60 °C (140 °F) ....................................................................................................... ............................................................................................... 0.48 - 0.68 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications > Page 653 Sealants And Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 654 Engine Coolant Temperature (ECT) Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 655 Engine Coolant Temperature (ECT) Sensor: Testing and Inspection ENGINE COOLANT TEMPERATURE SENSOR CHECK CAUTION: Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Drain engine coolant, then remove the engine coolant temperature sensor. 2. With the temperature sensing portion of engine coolant temperature sensor immersed in hot water, check the resistance. Standard value: 14 - 17 kOhm @ -20 °C (-4 °F) 5.1 - 6.5 kOhm @ 0 °C (32 °F) 2.1 - 2.7 kOhm @ 20 °C (68 °F) 0.9 - 1.3 kOhm @ 40 °C (104 °F) 0.48 - 0.68 kOhm @ 60 °C (140 °F) 0.26 - 0.36 kOhm @ 80 °C (176 °F) 3. If resistance deviates from the standard value greatly, replace the sensor. 4. Apply 3M AAD part number 8731 or equivalent to threaded portion. 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 ± 10 Nm (22 ± ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 656 Engine Coolant Temperature (ECT) Sensor: Service and Repair SEALANTS AND ADHESIVES ITEM .................................................................................................. .......................................................................................... SPECIFIED SEALANT Engine coolant temperature sensor threaded portion ....................................................................................................................................... MOPAR® Part No. 4318031or equivalent Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 662 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 663 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 664 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 665 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 666 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 667 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 668 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 669 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 670 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 671 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 672 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 673 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 674 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 675 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 676 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 677 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 678 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 679 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 680 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 681 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 682 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 683 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 684 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 685 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 686 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Engine Speed Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 693 Fuel Tank Pressure Sensor: Testing and Inspection FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK 1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991348 between the terminals of the disconnected connector. 2. Turn the ignition switch to "ON" and measure the output voltage between terminals 2 and 3. Standard value: 2.0 - 3.0 V Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 694 Special Tools Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake air temperature sensor resistance kOhm .................................................................................................................................. STANDARD VALUE -20 °C (-4 °F) ....................................................................................................................................... ....................................................................... 13 - 17 0 °C (32 °F) ..................................................... ......................................................................................................................................................... 5.3 - 6.7 20 °C (86° F) ......................................................................................................................... ................................................................................... 2.3 - 3.0 40 °C (104 °F) ................................... .............................................................................................................................................................. ......... 1.0 - 1.5 60 °C (140 °F) ............................................................................................................. ......................................................................................... 0.56 - 0.76 80 °C (176 °F) ......................... .............................................................................................................................................................. ............... 0.30 - 0.42 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 698 Intake Air Temperature (IAT) Sensor: Locations The Intake Air Temperature sensor is incorporated into the Mass Airflow Sensor and is not serviceable seperately. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 699 Intake Air Temperature (IAT) Sensor: Testing and Inspection INTAKE AIR TEMPERATURE SENSOR CHECK 1. Disconnect the volume air flow sensor connectors. 2. Measure resistance between terminals 5 and 6. Standard value: 13 - 17 kohm @ -20 °C (-4 °F) 5.3 - 6.7 kohm @ 0 °C (32 °F) 2.3 - 3.0 kohm @ 20 °C (68 °F) 1.0 - 1.5 kohm @ 40 °C (104 °F) 0.56 - 0.76 kohm @ 60 °C (140 °F) 0.30 - 0.42 kohm @ 80 °C (176 °F) 3. If not within specifications, replace the volume air flow sensor. 4. Measure resistance while heating the sensor using a hair dryer. Normal condition: TEMPERATURE RESISTANCE (kohm) Higher Smaller 5. If resistance does not decrease as heat increases, replace the volume air flow sensor assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 705 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 709 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 710 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 711 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 713 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 714 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 715 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 717 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 718 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 719 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 720 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 721 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 722 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 723 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 724 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 725 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 726 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 727 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated oxygen sensor output voltage V .............................................................................................. ...................................................................... 0.6 - 1.0 Heated oxygen sensor heater resistance Q ... .............................................................................................................................................................. .................................................... 4.5 - 8.0 .......................................................................................... .............................................................................................................................. 11 - 18 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 734 Oxygen Sensor: Locations View G Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 735 View b Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 736 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 737 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR CHECK Required Special Tools: - MB991658: Test Harness Set - MD998464: Test Harness 1. Using the scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MD998464 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [4.5 - 8.0 Ohm at 20 °C (68 °F) between terminal No.1 (red clip of special tool) and terminal No.3 (blue clip of special tool) on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.1 (red clip) of the heated oxygen sensor connector to the positive battery terminal and terminal No.3 (blue clip) to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.2 (black clip) and terminal No.4 (white clip). 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 738 NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. 1. Using scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MB991658 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [11 - 18 Ohm at 20 °C (68 °F) between terminal No.5 and terminal No.6 on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.5 of the heated oxygen sensor connector to the positive battery terminal and terminal No.6 to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.3 and terminal No.4. 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 739 Oxygen Sensor: Service and Repair REMOVAL AND INSTALLATION Removal And Installation Required Special - MD998770: Oxygen Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 740 Use special tool MD998770 to remove the oxygen sensor. INSTALLATION SERVICE POINT >>A<< RIGHT BANK HEATED OXYGEN SENSOR (FRONT)/RIGHT BANK HEATED OXYGEN SENSOR (REAR)/LEFT BANK HEATED OXYGEN SENSOR (REAR)/HEATED OXYGEN SENSOR (REAR) INSTALLATION Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 747 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 748 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 749 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 750 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 751 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations View D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 755 Vehicle Speed Sensor: Testing and Inspection VEHICLE SPEED SENSOR CHECK 1. Remove the vehicle speed sensor and connect a 3-10 kilo ohm resistor as shown in the illustration. 2. Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2 - 3. (1 turn = 4 pulses) 3. If within the standard value, the vehicle speed sensor is OK. If not within the standard value, replace the vehicle speed sensor. Standard value: Voltage alternates between 0 volt and 5 volts four times per turn. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 756 Vehicle Speed Sensor: Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 757 Disassembly And Assembly Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 762 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 763 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil pressure switch .............................................................................................................................. ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 770 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 771 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 772 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 773 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 774 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 779 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 780 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 781 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 782 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 788 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 791 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 793 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 794 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 796 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 797 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 798 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 799 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 800 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 801 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 802 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 803 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 804 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 805 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 806 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 807 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 808 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 809 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 810 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 811 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 812 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 818 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 820 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 821 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 823 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 824 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 825 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 826 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 827 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 828 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 829 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 830 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 831 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 832 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 833 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 834 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 835 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 836 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 837 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 838 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 839 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 840 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations View e Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 845 Impact Sensor: Service and Repair SIDE IMPACT SENSOR A side impact sensor is installed behind the quarter trim on both driver and passenger sides of the vehicle. Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 846 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 847 WARNING: If a dent, crack, deformation or rust is detected, replace with a new sensor. NOTE: For checking of the side impact sensor other than described below, refer to the section concerning SRS diagnosis. 1. Check the side impact sensor and bracket for dents, cracks or deformation. 2. Check the connector for damage, and terminal for deformation. 3. Check that there is no bending or corrosion in the quarter panel. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Overall View View P Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 854 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 859 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 860 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 861 Neutral Safety Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 862 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 863 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 864 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 865 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 866 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 867 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 868 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 869 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 870 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 871 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 872 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 873 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 874 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 875 Neutral Safety Switch: Testing and Inspection PARK/NEUTRAL POSITION SWITCH CONTINUITY CHECK PARK/NEUTRAL POSITION SWITCH CONTINUITY CHECK Part 1 of 2 Part 2 of 2 NOTE: For vehicles with sport mode, four positions (P, R, N, D) are used. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 876 Neutral Safety Switch: Adjustments PARK/NEUTRAL POSITION SWITCH AND CONTROL CABLE ADJUSTMENT 1. Set the selector lever to the "N" position. 2. Loosen the control cable to the manual control lever coupling nut to free the cable and lever. 3. Set the manual control lever to the neutral position. 4. Loosen the park/neutral position switch body mounting bolts and turn the park/neutral position switch body so the hole in the end of the manual control lever and the hole (section A - A in the figure on the left) in the flange of the park/neutral position switch body flange are aligned. NOTE: The park/neutral position switch body can be aligned by inserting a 5-mm diameter steel bar into the end hole of the manual control lever and the flange hole of the park/neutral position switch body. 5. Tighten the park/neutral position switch body mounting bolts to the specified torque. Be careful at this time that the switch body does not move. Tightening torque:...............11 ± 1 Nm (96 ± 8 inch lbs.) 6. Gently push the transaxle control cable in the direction of the arrow, until the cable is taut. Tighten the adjusting nut. Tightening torque:.................12 ± 2 Nm (107 ± 17 inch lbs.) 7. Check that the selector lever is in the "N" position. 8. Check that each position of the manual control lever matches each position of the selector lever and using scan tool. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection F4A42 - Automatic Transmission INSPECTION SHIFT SWITCH ASSEMBLY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Testing and Inspection Transmission Temperature Sensor/Switch: Testing and Inspection A/T FLUID TEMPERATURE SENSOR CONTINUITY CHECK 1. Remove the A/T fluid temperature sensor. 2. Measure the resistance between terminals No. 1 and No.2 of the A/T control solenoid valve assembly connector. Standard value: 3. If the A/T fluid temperature sensor resistance is not consistent with the fluid temperature, replace A/T fluid temperature sensor. NOTE: The N range indicator light on the combination meter flashes when the temperature reaches approximately 125°C (257°F) or higher, and then Stops flashing when the temperature drops below approximately 115°C (23-wF). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Testing and Inspection Defogger Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Testing and Inspection > Page 897 Heated Glass Element Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Heater Control Assembly and Blower Switch Assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check Power Window Switch: Testing and Inspection Power Window Main Switch Check Power Window Main Switch Check Power Window Main Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 902 Power Window Main Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 903 Power Window Switch: Testing and Inspection Power Window Sub Switch Check Power Window Sub Switch Check Power Window Sub Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 904 Power Window Switch: Testing and Inspection Power Window Sub Switch Illumination Check Power Window Sub Switch Check Power Window Sub Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Testing and Inspection Washer Fluid Level Switch: Testing and Inspection WASHER FLUID LEVEL SWITCH CHECK Connect a circuit tester to the connector of the level sensor as shown. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test Windshield Washer Switch: Testing and Inspection Windshield Wiper/Washer Switch Test WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK Check continuity between the switch terminals. WINDSHIELD INTERMITTENT WIPER VOLUME CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test > Page 913 Check that the resistance varies between 0 and 1 kilo ohm when the windshield intermittent volume is turned from FAST to SLOW by measuring resistance between connector terminals 27 and 28 at the column switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test > Page 914 Turn-signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems Turn-signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems > Page 919 Wiper Switch: Testing and Inspection Windshield Wipers and Washers WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK Check continuity between the switch terminals. WINDSHIELD INTERMITTENT WIPER VOLUME CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems > Page 920 Check that the resistance varies between 0 and 1 kilo ohm when the windshield intermittent volume is turned from FAST to SLOW by measuring resistance between connector terminals 27 and 28 at the column switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Alignment: Specifications Front FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT Required Special Tool: - MB991004: Wheel Alignment Gauge Attachment. Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition before measuring wheel alignment. TOE-IN Standard value: 0 ± 3 mm (0 ± 0.12 inch) 1. Adjust the toe-in by undoing the clip and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. 2. Use a turning radius gauge to check that the steering angle is at the standard value. STEERING ANGLE Standard value: CAMBER AND CASTER Standard value: Camber 0 ° 00' ± 30'(Left/right deviation within 30') Caster 3 ° 00' ± 30'(Left/right deviation within 30') NOTE: Caster is preset at the factory and cannot be adjusted. CAUTION: Never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened. NOTE: For vehicles with aluminum type wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool MB991004. Tighten special tool MB991004 to the same torque 226 ± 29 Nm (167 ± 21 ft. lbs.) as the driveshaft nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front > Page 926 If the camber is outside of the standard value, perform the following adjustment procedures. 1. Estimate how much additional camber adjustment is required. Using the table below, select the camber adjusting bolt, and then replace the knuckle and strut assembly connection bolts (upper bolt, lower bolt) with the selected bolts. NOTE: Set bolt is the bolt installed at factory. "10 " embossed on bolt head is head mark. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front > Page 927 2. Tighten the nuts temporarily, and then pull or push the front axle to adjust the camber. NOTE: Pulling the upper side of the front axle to the outside of the vehicle will increase the camber. Pushing it to the inside of the vehicle will decrease the camber. 3. Tighten the nuts to 300 ± 24 Nm (221 ± 18 ft. lbs.). 4. Recheck the camber. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front > Page 928 Alignment: Specifications Rear REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure wheel alignment with an alignment equipment on level ground. The rear suspension and wheels should be serviced to the normal condition prior to wheel alignment. TOE-IN Standard value: 3 ± 3 mm (0.12 ± 0.12 inch) Loosen nut, then turn the toe control arm mounting bolt to adjust toe. NOTE: LH: Clockwise viewed from the rear -> Toe-out - RH: Clockwise viewed from the rear -> Toe-in - Toe adjustment can be made at graduations of approximately 2.5 mm (0.10 inch). CAMBER Standard value: -1°20'+ 30' (Difference between right and left within 30') NOTE: Camber is preset at the factory and cannot be adjusted. NOTE: If camber is not within the standard value, check and replace bent or damaged parts. Dimension for positioning upper arm bracket mm (in) ............................................................................................................... 37.2 +/-2 (1.46 +/- 0.08) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension Alignment: Service and Repair Front Suspension FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT Required Special Tool: - MB991004: Wheel Alignment Gauge Attachment. Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition before measuring wheel alignment. TOE-IN Standard value: 0 ± 3 mm (0 ± 0.12 inch) 1. Adjust the toe-in by undoing the clip and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. 2. Use a turning radius gauge to check that the steering angle is at the standard value. STEERING ANGLE Standard value: CAMBER AND CASTER Standard value: Camber 0 ° 00' ± 30'(Left/right deviation within 30') Caster 3 ° 00' ± 30'(Left/right deviation within 30') NOTE: Caster is preset at the factory and cannot be adjusted. CAUTION: Never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened. NOTE: For vehicles with aluminum type wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool MB991004. Tighten special tool MB991004 to the same torque 226 ± 29 Nm (167 ± 21 ft. lbs.) as the driveshaft nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension > Page 931 If the camber is outside of the standard value, perform the following adjustment procedures. 1. Estimate how much additional camber adjustment is required. Using the table below, select the camber adjusting bolt, and then replace the knuckle and strut assembly connection bolts (upper bolt, lower bolt) with the selected bolts. NOTE: Set bolt is the bolt installed at factory. "10 " embossed on bolt head is head mark. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension > Page 932 2. Tighten the nuts temporarily, and then pull or push the front axle to adjust the camber. NOTE: Pulling the upper side of the front axle to the outside of the vehicle will increase the camber. Pushing it to the inside of the vehicle will decrease the camber. 3. Tighten the nuts to 300 ± 24 Nm (221 ± 18 ft. lbs.). 4. Recheck the camber. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension > Page 933 Alignment: Service and Repair Rear Suspension REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure wheel alignment with an alignment equipment on level ground. The rear suspension and wheels should be serviced to the normal condition prior to wheel alignment. TOE-IN Standard value: 3 ± 3 mm (0.12 ± 0.12 inch) Loosen nut, then turn the toe control arm mounting bolt to adjust toe. NOTE: LH: Clockwise viewed from the rear -> Toe-out - RH: Clockwise viewed from the rear -> Toe-in - Toe adjustment can be made at graduations of approximately 2.5 mm (0.10 inch). CAMBER Standard value: -1°20'+ 30' (Difference between right and left within 30') NOTE: Camber is preset at the factory and cannot be adjusted. NOTE: If camber is not within the standard value, check and replace bent or damaged parts. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure kPa (psi) Vacuum hose disconnected ................................................................................................................................................... 330 350 (47 - 50) at curb idle Vacuum hose connected ............................................................................................................................................... Approximately 270 (38) at curb idle Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 938 Fuel Pressure: Testing and Inspection FUEL PRESSURE TEST Required Special Tools: - MB9915Q2: Scan Tool (MUT-II) - MB991637: Fuel Pressure Gauge Set - MD998709: Adaptor Hose - MD998742: Hose Adaptor 1. Release residual pressure from the fuel line to prevent fuel spray. WARNING To prevent a fire, cover the hose connection with shop towels to prevent splashing of fuel that could be caused by Some residual pressure in the fuel pipe line. 2. Disconnect the high-pressure fuel hose at the fuel rail side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 939 3. Assemble the fuel pressure measurement tools as follows. 1. Rempve the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Place a suitable O-ring or gasket on assembled special tools MD998709 and MD998742 and install the fuel pressure gauge. 3. Install the assembled fuel pressure measurement tools between the fuel rail and high-pressure fuel hose. 1. Remove the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Install special tool MB991637 (fuel pressure gauge set) to assembled special tools MD998709 and MD998742 via a gasket. 3. Install the assembled fuel pressure measurement tools between the fuel rail and the high-pressure fuel hose. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 4. Connect scan tool MB991502 to the data link connector. 5. Use the Actuator test 07 to drive the fuel pump. Check that there is no fuel leaking from any section when the fuel pump is operating. 6. Stop the fuel pump. 7. Start the engine and run at idle. 8. Measure fuel pressure while the engine is running at idle. Standard value: Approximately 270 kPa (38 psi) at curb idle 9. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed with your finger. Standard value: 330 - 350 kPa (47 - 50 psi) at curb idle 10. Check to see that fuel pressure at idle does not drop even after the engine has been revved several times. 11. Revving the engine repeatedly, hold the fuel return hose lightly with your fingers to feel that fuel pressure is present in the return hose. NOTE:If the fuel flow rate is low, there will be no fuel pressure in the return hose. 12. If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 940 13. Stop the engine and observe fuel pressure gauge reading. It is normal if the reading does not drop within two minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Start, then stop the engine. 1. Squeeze the fuel return line closed to confirm leak-down occurs from defective fuel pressure regulator. 2. Squeeze the fuel supply line closed to confirm leak-down occurs from defective fuel pump check valve. 3. If pressure continues to drop with both fuel lines squeezed closed, injector(s) are leaking. 14. Release residual pressure from the fuel pipe line. WARNING Cover the hose connection with shop towels to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. 15. Remove the fuel pressure gauge, and special tools MD998709 and MD998742 from the fuel rail. 16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. 17. Fit the high-pressure fuel hose into the fuel rail and tighten the bolts to specified torque. Tightening torque: 4.9 ± 1.0 (44 ± 8 in. lbs.) 18. Check for fuel leaks. 1. Use scan tool MB991502 to operate the fuel pump. 2. Check the fuel tine for leaks, and repair as needed. 19. Disconnect scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection IDLE MIXTURE CHECK Required Special Tool: MB991502: Scan Tool (MUT-II) 1. Before inspection, set vehicles in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector: 3. Check that the basic ignition timing is within the standard value. Standard value: 5 ± 3 °BTDC 4. Start the engine and increase the engine speed to 2,500 rpm for 2 minutes. 5 Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value: CO contents: 0.5 % or less HC contents: 100 ppm or less 7. If the CO and HC contents do not remain inside the standard value; check the following items: NOTE: Replace the catalytic converter when the CO and HC contents do not remain inside the standard value, even though the result of the inspection is normal for all items. ^ Diagnosis output ^ Closed-loop control (When the closed-loop control is carried out normally, the output signal of the heated oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) ^ Fuel pressures ^ Injector ^ Ignition coil, spark plug cable, spark plug ^ EGR system and EGR valve leak ^ Evaporative emission control system ^ Compression pressure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Basic idle speed .................................................................................................................................. .............................................................. 700 ± 50 rpm Curd idle speed .............................................. ................................................................................................................................................. 700 ± 100 rpm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 947 Idle Speed: Testing and Inspection CURB IDLE SPEED CHECK Required Special Tool: ^ MB991502: Scan Tool (MUT-II) 1. Before inspection and adjustment set vehicles in the following condition. ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB99150 2. 2. Connect scan tool MB991502 to the data link connector. 3. Check the basic ignition timing. Standard value: 5 ± 3 °BTDC 4. Start the engine. 5 Run the engine at idle for 2 minutes. 6. Check the idle speed. Select item number 22 and take a reading of the idle speed. Curb idle speed: 700 ± 100 rpm NOTE: The idle speed is controlled automatically by the idle air control system. 7. If the idle speed is outside the standard value, refer to Multiport Fuel Injection (MFI) Diagnosis Symptom Chart. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 948 Idle Speed: Adjustments BASIC IDLE SPEED ADJUSTMENT Required Special Tool: - MB991502: Scan Tool (MUT-II) NOTE: The standard idle speed has been adjusted with the speed adjusting screw (SAS), by the manufacturer, and there should be no need for readjustment. NOTE: If the adjustment has been changed by mistake, the idle speed may become too high Qr the idle speed may drop too low when loads A/C, defogger, etc. are placed on the engine. If this occurs, adjust by the following procedure. NOTE: The adjustment; if made, should be made after first confirming that the spark plugs, the injectors, the idle air control motor, compression, etc., are all normal. 1. The vehicle should be prepared as follows before the inspection and adjustment. - Engine coolant temperature: 80 - 95 °C (176 - 203 °F) - Lights, electric cooling fan and accessories: OFF - Transaxie: Neutral (A/T for "P" range) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting Qr disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector (16-pin). 3. Start the engine and run at idle. 4. Select the item number 30 of the scan tool Actuator test. NOTE: Use the scan tool to hold the IAC motor at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 700 ± 50 rpm NOTE: The engine speed may be 20 to 100 rpm lower than indicated above for a new vehicle [driven approximately 500 km (300 mile) or less, but no adjustment is necessary. If the engine stalls or the engine speed is low even though the vehicle has been driyen approximately 500 km (300 mile) or more, it is probable that deposits are adhered to the throttle valve, so clean it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 949 6. If not withih the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment. 7. Press the recan tool clear key, and release the IAC motor Actuator test mode. 8. Turn the ignition switch to the "LOCK" (OFF) position. NOTE: Unless the IAC motor is released, the Actuator Test Mode will continue for 27 minutes. 9. Disconnect scan tool MB991502. 10. Start the engine again and let it idle for about 10 minutes. Check that the idling condition is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications Air Cleaner Housing: Specifications Air cleaner bolt ..................................................................................................................................... ................................... 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications > Page 953 Air Cleaner Housing: Diagrams AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications > Page 954 Air Cleaner Housing: Service and Repair AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 959 Fuel Pressure Release: Service and Repair FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the instrument panel side cover (driver's side). 2. Disconnect the fuel pump relay (2). 3. Start the engine and let it run until it stops naturally. Turn the ignition switch to the "LOCK" (OFF) position. 4. Connect the fuel pump relay (2). 5. Install the instrument panel side cover (driver's side). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION - 2.4L ENGINE The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft with hydraulic lifters and four valve per cylinder design. The engine is free-wheeling; meaning it has provisions for piston-to-valve clearance. However valve-to-valve interference can occur, if camshafts are rotated independently. cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 964 Firing Order: Mechanical Specifications Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Measure the resistance of the all spark plug leads. 1. Check the cap and coating for cracks. 2. Measure the resistance. Limit: 19 kilo ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................ 0.039 - 0.043 in. (1.0 - 1.1 mm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 979 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................... 18 +/- 4 ft-lb (25 +/- 4 Nm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 980 Spark Plug: Testing and Inspection SPARK PLUG CHECK AND CLEANING <2.4L ENGINE> 1. Check that the plug is not burned, that the insulator plug is not damaged, and that the seizure state is good. 2. If cleaning is required due to carbon deposits, etc., clean using a plug cleaner or wire brush, etc. 3. Check the plug gap using a plug gap gauge, and adjust if not within the standard value. Standard value: 1.0 - 1.1mm (0.039 - 0.043 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressure ........................................................................................................................ ........................................................... (250 - 400 rpm) Standard Value .................................................................................................................................... ................................................ 1,275 kPa (185 psi) Limit (Minimum) ................................................................................................................................... .......................................... 959 kPa (139 psi) Compression pressure difference of all cylinder Limit ..................................................................................................................................................... ............................................... 98 kPa (14 psi) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 984 Compression Check: Testing and Inspection COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights, and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crankshaft position sensor connector. NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel injection. WARNING: Keep your distance from the spark plug hole when cranking. Oil, fuel, etc., may spray out from the spark plug hole and may cause serious injury. 5 Cover the spark plug hole with a shop towel etc., during cranking. After the engine has been cranked, check for foreign material adhering to the shop towel. 6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 - 400 rpm): 1,275 kPa (185 psi) Minimum limit (at engine speed of 250 - 400 rpm): 959 kPa (139 psi) 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: 98 kPa (14 psi) 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 to 8. 1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/ or cylinder inner surface. 2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crankshaft position sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the scan tool to erase the diagnostic trouble codes. NOTE: This will erase the diagnostic trouble code resulting from the crankshaft position sensor connector being disconnected. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Timing Belt Timing Belt: Diagrams Timing Belt TIMING BELT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Diagrams > Timing Belt > Page 989 Timing Belt: Diagrams Timing Belt B TIMING BELT B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Timing Belt: Service and Repair Timing Belt TIMING BELT REMOVAL AND INSTALLATION Required Special Tools: ^ MD998738: Adjusting Screw ^ MD998767: Tensioner Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 992 1. Turn the crankshaft in the forward direction (to the right) to align the camshaft sprocket timing marks. 2. Loosen the tension pulley fixing bolt. CAUTION: If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. 3. Move the tension pulley to the water pump side, and then remove the timing belt. INSTALLATION SERVICE POINTS >>A<< AUTO-TENSIONER INSTALLATION 1. Apply 98 - 196 N (22 - 44 lbs.) force to the pushrod of the auto-tensioner by pressing it against a metal object (such as the engine block) and measure the movement of the pushrod. Standard value: Within 1 mm (0.04 in.) A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 2. If it is outside the standard value, replace the auto-tensioner. CAUTION: Never compress the pushrod too fast, or it may be damaged. 3. Use a press or vise to gently compress the auto-tensioner pushrod until pin hole A of the pushrod and pin hole B of the tensioner cylinder are aligned. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 993 4. When the holes are aligned, insert the set pin. NOTE: When replacing the auto-tensioner with a new part, the pin will be in the auto-tensioner. 5. Install the auto-tensioner to the engine. >>B<< TIMING BELT INSTALLATION 1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket. 2. After aligning the timing mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips) head 8 mm (0.3 in.) screwdriver. Check to be sure that the screwdriver goes in 60 mm (2.4 inches) or more. If the screwdriver will only go in 20 - 25 mm (0.8 - 1.0 in.) before striking the counterbalance shaft, turn the sprocket once, realign the timing marks and check that the screwdriver goes in 60 mm (2.4 inches) or more. The screwdriver should not be taken out until the timing belt is installed. CAUTION: If the timing belt is re-used, install so that the arrow marked on it at time of removal is pointing in the clockwise direction. 3. Install the belt to the crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order, so that there is no slackness in the belt tension. 4. Set the tension pulley so that the pin holes are at the bottom, press the tension pulley lightly against the timing belt, and then provisionally tighten the fixing bolt. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 994 5 Adjust the timing belt tension. >>C<< TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft 1/4 of a revolution in the counterclockwise direction, turn it in the clockwise direction until the timing marks are aligned. CAUTION: When tightening the fixing bolt, make sure that the tension pulley does not turn with the bolt. 2. Loosen the tension pulley fixing bolt, and then use special tool MD998767 and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the timing belt. Timing belt tension torque: 3.5 Nm (31 in. lbs.) Tightening torque: 48 ± 6 Nm (36 ± 4 ft. lbs.) 3. Remove the set pin that has been inserted into the auto-tensioner. 4. Turn the crankshaft two revolutions clockwise so that the timing marks are aligned. After leaving it for 15 minutes, measure the amount of protrusion of the auto-tensioner. Standard value (A): 3.8 - 4.5 mm (0.15 - 0.18 in.) 5 If the amount of protrusion is outside the standard value, repeat steps (1) through (4). 6. Check again to be sure that the timing marks of each sprocket are aligned. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 995 Timing Belt: Service and Repair Timing Belt B TIMING BELT B REMOVAL AND INSTALLATION Required Special Tool: ^ MB991367: Special Spanner REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 996 CAUTION: If the belt is to be re-used, mark an arrow on the belt with chalk indicating the clockwise direction of rotation. INSTALLATION SERVICE POINTS >>A<< TIMING BELT B INSTALLATION 1. Ensure that crankshaft sprocket B timing marks and the counterbalance shaft sprocket timing marks are aligned. 2. Fit timing belt B over crankshaft sprocket B and the counterbalance shaft sprocket. Ensure that there is no slack in the belt. >>B<< CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION 1. To prevent the crankshaft bolt from loosening, degrease or clean the seating surfaces of the crankshaft, crankshaft sprocket B, crankshaft sensing blade and crankshaft at the shown positions. 2. Install the crankshaft sensing blade so that they face as shown in the illustration. 3. Apply the minimum amount of engine oil to the seat surface and thread of the crankshaft bolt. 4. Use the crankshaft pulley mounting bolt to secure special tool MB991367. 5 Tighten the crankshaft sprocket bolt to the specified torque. Tightening torque: 118 ± 9 Nm (87 ± 7 ft. lbs.) >>C<< TIMING BELT B TENSION ADJUSTMENT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 997 1. Temporarily fix the timing belt B tensioner so the center of the tensioner pulley is to the left and above the center of the mounting bolt. Temporarily attach the tensioner pulley so the flange is toward the front of the engine. CAUTION: When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension of the bolt. 2. Holding the timing belt B tensioner up with your finger in the direction of the arrow, apply pressure on the timing belt so the tension side of the belt is taut. Now tighten the bolt to fix the tensioner. Tightening torque: 19 ± 3 Nm (14 ± 2 ft. lbs.) 3. To ensure that the tension is correct, depress the belt (point A) with a finger. Adjust the belt tension if it is incorrect. Standard value: 5 - 7 mm (0.2 - 0.3 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Specifications Air Cleaner Housing: Specifications Air cleaner bolt ..................................................................................................................................... ................................... 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Specifications > Page 1005 Air Cleaner Housing: Diagrams AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Specifications > Page 1006 Air Cleaner Housing: Service and Repair AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1014 Fuel Pressure Release: Service and Repair FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the instrument panel side cover (driver's side). 2. Disconnect the fuel pump relay (2). 3. Start the engine and let it run until it stops naturally. Turn the ignition switch to the "LOCK" (OFF) position. 4. Connect the fuel pump relay (2). 5. Install the instrument panel side cover (driver's side). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > ENGINE LUBRICATION - WARNING! INCORRECT OIL FILTER USE Oil Filter: Technical Service Bulletins ENGINE LUBRICATION - WARNING! INCORRECT OIL FILTER USE NUMBER: 09-011-04 GROUP: Engine DATE: April 27, 2004 SUBJECT: Incorrect Oil Filter Usage OVERVIEW: This bulletin describes proper oil filter usage for the two different 2.4L engines. MODELS: 2001 - 2005 JR Sebring Convertible/Sebring Sedan/Stratus Sedan 2001 - 2005 ST Sebring/Stratus Coupe DISCUSSION: When performing scheduled maintenance, it is critical to use the correct oil filter to prevent engine damage. There may be some confusion between the two different 2.4L engines that have been used from model years 2001 through 2005. One 2.4L engine (DOHC) manufactured by Daimlerchrysler is used in the Sebring Convertible, Sebring Sedan and Stratus Sedan. The oil filter used for this engine is p/n 04105409. The second 2.4L engine (SOHC) is manufactured by Mitsubishi Motors Corporation (MMC). This engine is used in the Sebring Coupe and Stratus Coupe. The oil filter used for this engine is p/n MD360935. CAUTION: The MMC oil filter could be incorrectly installed on a DaimlerChrysler built 2.4L engine. Use of the MMC oil filter on a DaimlerChrysler built 2.4L engine will result in engine damage due to oil loss. POLICY: Information Only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1019 Oil Filter: Specifications Oil filter part number MD360935 ............................................................................................................................................ 14 ± 2 Nm (122 ± 17 in. lbs.) Oil filter other than MITSUBISHI genuine filter ......................................................................................................................... 17 ± 2 Nm (13 ± 1 ft. lbs.) Oil filter bracket bolt ..................................................................................................................... ............................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water hose and water pipe Thermostat case bolt ........................................................................................................................... ..................................... 23 ± 4 Nm (17 ± 3 ft. lbs.) Water inlet pipe assembly bolt ............................................................................................................................................ 13 ± 2 Nm (109 ± 21 in. lbs.) Water outlet fitting bolt ....................................................................................................................................................... 13 ± 2 Nm (109 ± 21 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications > Page 1024 Coolant Line/Hose: Diagrams WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION <2.4L ENGINE> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications > Page 1025 Coolant Line/Hose: Service and Repair WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION <2.4L ENGINE> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications > Page 1026 <3.0L ENGINE> REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications > Page 1027 >>A<< O-RING INSTALLATION CAUTION Do not allow engine oil or other grease to adhere to the O ring. Install the O-ring to the water pipe, and coat the outer portion of the O-ring with water or engine coolant >>B<< WATER OUTLET FITTING <2.4L Engine>/ THERMOSTAT CASE ASSEMBLY <2.4L Engines INSTALLATION Apply a continuous bead of MITSUBISHI GENUINE Sealant Part number MD970389 or equivalent to the thermostat housing mating surface. >>C<< RADIATOR UPPER/LOWER HOSE CONNECTION 1. Insert each hose as far as the projection of the water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose. INSPECTION Water Pipe and Hose Check Check the water pipe and hose for cracks, damage and clogs. Replace them if necessary. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair Hose/Line HVAC: Service and Repair Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Oil Pump eye bolt 42 +/- 5 ft. lb. Oil reservoir, pressure hose, pressure tube, return tube, cooler tube bolt 100 +/- 22 in. lb. Pressure tube flare nut (Gear Box side) 11 +/- 2 ft. lb. Pressure tube flare nut (Pressure Hose side) 26 +/- 3 ft. lb. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1034 Power Steering Line/Hose: Service and Repair POWER STEERING HOSES <2.4L ENGINE> REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1035 <3.0L ENGINE> INSTALLATION SERVICE POINTS >>A<< PRESSURE TUBE ASSEMBLY INSTALLATION Align the marks on the pressure tube assembly and steering gear box, and install the pressure tube assembly. >>B<< RETURN HOSE ASSEMBLY INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1036 1. Align the marks on the return hose assembly and steering gear box, and install the return hose assembly. 2. Install the return hose assembly so that the marking is positioned as shown in the illustration. >>C<< PRESSURE HOSE INSTALLATION 1. Install the pressure hose at the gear box side so that the marking is positioned as shown in the illustration. 2. Install the pressure hose at the power steering oil pump side as shown in the illustration. >>D<< RETURN HOSE INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1037 Install the return hose so that the markings are positioned as shown in the illustration. >>E<< SUCTION HOSE INSTALLATION Install the suction hose so that the markings are positioned as shown in the illustration. >>F<< RETURN HOSE INSTALLATION Install the-return hose so that the markings are positioned as shown in the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Fill to the Full mark on the brake fluid reservoir. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 1043 Brake Fluid: Fluid Type Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 * If DOT 3 brake fluid is not available, DOT 4 or DOT 4+ is acceptable. Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .............................................. 7.0 Liters ( 7.4 qts ) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1048 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1049 Coolant: Testing and Inspection ENGINE COOLANT LEAK CHECK WARNING: When pressure testing the cooling system, slowly release cooling system pressure to avoid gaffing burned by hot coolant. CAUTION: ^ Be sure to completely clean away any moisture from the places checked. ^ When the tester is taken out, be careful not to spill any coolant from it. ^ Be careful when installing and removing the tester and when testing not to deform the filler neck of the radiator. 1. Check that the coolant level is up to the filler neck. Install a radiator cap tester and apply 160 kPa (23 psi) pressure, and then check for leakage from the radiator hose or connections. 2. If there is leakage, repair or replace the appropriate part. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage NUMBER: 21-021-05 GROUP: Transmission DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-003-02, DATED JULY 29, 2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS, REVISED DISCUSSION AND REVISED PARTS REQUIRED SECTION. SUBJECT: ATF+4 Usage OVERVIEW: This bulletin provides information about ATF+4 usage in ST22 models. MODELS: 2001 - **2005** (ST) Sebring/Stratus Coupe DISCUSSION: ATF+4 (type 9602) is approved for use in Sebring/Stratus Coupe power steering and automatic transaxles. The fluid is fully compatible in power steering systems and no additional maintenance information is required. When using ATF+4 in automatic transaxles, the following information is required for proper service and maintenance. SCHEDULED MAINTENANCE When using ATF+4 as a complete fill in Sebring/Stratus Coupe models, the maintenance for schedule A is changed to a 60,000 mile fluid replacement interval. Schedule B remains the same as listed in the owners manual. The owner should be notified about this schedule change when ATF+4 is used as a complete fill. NOTE: Using ATF+4 for top off will not change the original characteristics of the factory fill or original maintenance schedule. GENERAL SERVICE FILL ATF+4 is fully compatible for top off or for any transaxle service procedures that would require fluid fill or fluid replacement. Special considerations are required if a new torque converter is installed. TORQUE CONVERTER REPLACEMENT If a new torque converter is installed, ATF+4 can be used however, green torque converter shudder MAY be experienced. If green torque converter shudder is experienced, it will be eliminated over time as the torque converter clutches wear or burnish in. If shudder occurs, the vehicle can be driven (in torque converter partial lockup) until the condition is eliminated. **The table below lists the speeds to drive the vehicle to achieve torque converter partial lock up. If customer concerns arise due to green torque converter shudder and will not accept the normal burnishing procedure, use the following procedure.** NOTE: **To eliminate any concerns of green torque converter shudder, the transaxle can be filled with Diamond SPIII fluid during the initial fill**. 1. Drain and refill the transaxle with a minimum of 80% Diamond SPIII Transmission Fluid. NOTE: **Diamond SPIll fluid is available from Mitsubishi dealers.** 2. Warm the transaxle (by driving) to a minimum of 40° C (104° F). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 1054 3. Drive the vehicle for 50 kilometers (30 miles) in a speed range to keep the transaxle torque converter in partial lock up. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 1055 Fluid - A/T: Technical Service Bulletins A/T - ATF Fluid Coloration/Filling Precautions NUMBER: 21-003-03 GROUP: Transmission DATE: Mar. 28, 2003 SUBJECT: Automatic Transmission Fluid (ATF) Color MODELS: 2003 (ST) Sebring Coupe/Stratus Coupe NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION (SALES CODES DGI, DGB, OR DHD) BUILT ON AND INCLUDING FEBRUARY 7, 2003 THROUGH AND INCLUDING MARCH 3, 2003. DISCUSSION: Automatic Transmission Fluid (ATF) delivery to the assembly plant did not have the appropriate red dye added during the refining process. The ATF color for the models listed above appears clear to slightly yellow/orange instead of the typical red color. Laboratory testing has confirmed the ATF meets all specifications and does not create any performance issues. It is not necessary to change the transmission fluid due to the lack of red dye. Since the fluid is nearly clear, it is difficult to see on the dipstick. When checking fluid level on one of these models, carefully check the dip stick level to avoid overfilling the transmission. POLICY: Information Only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 1056 Fluid - A/T: Technical Service Bulletins A/T, Power Steering - ATF+4 Fluid Usage NUMBER: 21-003-02 GROUP: Transmission DATE: Jul. 29, 2002 SUBJECT: ATF+4 Usage OVERVIEW: This bulletin provides information about ATF+4 usage in ST22 models. MODELS: 2001 - 2003 (ST) Sebring/Stratus Coupe DISCUSSION: ATF+4 (type 9602) is approved for use in Sebring/Stratus Coupe power steering and automatic transaxles. The fluid is fully compatible in power steering systems and no additional maintenance information is required. When using ATF+4 in automatic transaxles, the following information is required for proper service and maintenance. SCHEDULED MAINTENANCE When using ATF+4 as a complete fill in Sebring/Stratus Coupe models, the maintenance for schedule A is changed to a 60,000 mile fluid replacement interval. Schedule B remains the same as listed in the owners manual. The owner should be notified about this schedule change when ATF+4 is used as a complete fill. NOTE: USING ATF+4 FOR TOP OFF WILL NOT CHANGE THE ORIGINAL CHARACTERISTICS OF THE FACTORY FILL OR ORIGINAL MAINTENANCE SCHEDULE. GENERAL SERVICE FILL ATF+4 is fully compatible for top off or for any transaxle service procedures that would require fluid fill or fluid replacement. Special considerations are required if a new torque converter is installed. TORQUE CONVERTER REPLACEMENT If a new torque converter is installed, ATF+4 can be used however, green torque converter shudder MAY be experienced. If green torque converter shudder is experienced, it will be eliminated over time as the torque converter clutches wear or burnish in. If shudder occurs, the vehicle can be driven (in torque converter partial lockup) until the condition is eliminated. If customer concerns arise due to green torque converter shudder use the following procedure. NOTE: TO ELIMINATE ANY CONCERNS OF GREEN TORQUE CONVERTER SHUDDER, THE TRANSAXLE CAN BE FILLED WITH DIAMOND SPIII FLUID PN 05073942AA DURING THE INITIAL FILL. 1. Drain and refill the transaxle with a minimum of 80% Diamond SPIII Transmission Fluid pn 05073942AA. 2. Warm the transaxle (by driving) to a minimum of 40 degrees C (104 degrees F). 3. Drive the vehicle for 50 kilometers (30 miles) in a speed range as shown to keep the transaxle torque converter in partial lock up. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 1057 PARTS REQUIRED POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Fluid - A/T: Pressure, Vacuum and Temperature Specifications Line pressure ....................................................................................................................................... .............................. 1,010 - 1,050 kPa (147 - 152 psi) A/T fluid temperature sensor @ 0 °C (32 °F) ..................................................................................................................................... ................................................... 16.7 - 20.5 ohms @ 20 °C (68 °F) ................................................... ....................................................................................................................................... 7.3 - 8.9 ohms @ 40 °C (104 °F) ....................................................................................................................... ................................................................. 3.4 - 4.2 ohms @ 60 °C (140 °F) ....................................... ................................................................................................................................................. 1.9 2.2 ohms @ 80 °C (176 °F) ................................................................................................................. ....................................................................... 1.0 - 1.2 ohms @ 100 °C (212 °F) ............................... ................................................................................................................................................... 0.57 0.69 ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1060 Fluid - A/T: Capacity Specifications Fluid Capacity ...................................................................................................................................... ...................................................... 7.7Liters (8.1 Qt) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1061 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ............................... Mitsubishi Genuine ATF SP III Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement Fluid - A/T: Service and Repair A/T Fluid Replacement Automatic Transmission Fluid Replacement Procedure If you have an transmission fluid changer, use this chapter to replace the transmission fluid. If you do not have an transmission fluid changer, replace the transmission fluid by the following procedure. 1. Disconnect the hose show in the illustration which connects the transaxle and the oil cooler (inside the radiator). Place a container under the hose to collect the discharge. Caution: The engine should be stopped within one minute after it is started. If all the transmission fluid has drained out before then, the engine should be stopped at that point. 2. Start the engine and let the transmission fluid drain out. - Running Conditions: "N" range with engine idling Note: Approximately 3.5 dm ( 3.7 quarts ) of transmission fluid should be removed. 3. Remove the drain plug from the bottom of the transaxle case to drain the transmission fluid. - Approximately 2.0 dm ( 2.1 quarts ) of transmission fluid should be removed. 4. Install the drain plug with a new gasket, and tighten it to the specified torque. - Tighten torque 32 ± 2 Nm ( 24 ft lbs ). Caution: Stop pouring if the full volume of transmission fluid cannot be added. 5. Add new transmission fluid ( DIAMOND ATF SP III or equivalent ) through the oil filler tube. - Approximately 5.5 dm ( 5.8 quarts ) transmission fluid should be added. 6. Repeat the procedure in step 2, ( to pump out the rest of the contaminated transmission fluid ). 7. Add new transmission fluid ( DIAMOND ATF SP III or equivalent ) through the oil filler tube. - Approximately 3.5 dm ( 3.7 quarts ) transmission fluid should be added. Note: Check for contamination or a burnt odor. If the transmission fluid is contaminated or burnt, repeat steps 6 and 7 before proceeding to step 8. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement > Page 1064 8. Reconnect the hose which was disconnect in step 1 above, and firmly replace the dipstick. 9. Start engine and run it at idle for one to two minutes. 10. Move the selector lever through all positions, and then move it to the "N" position. 11. Check that the transmission fluid level is at the "COLD" mark on the dipstick. If the level is less than this, add transmission fluid. 12. Drive the vehicle until the transmission fluid temperature ruses to the normal operating temperature ( 70 - 80 ° C ( 158 - 176 ° F )) and then check the transmission fluid level again. The transmission fluid level must be at the "HOT" mark. Note: The A/T fluid temperature is measured with scan tool MB991502 ( MUT II ). Note: The "COLD" level is for reference only, the "HOT" level should be regarded as the standard level. Note: If it takes some amount of time until the A/T fluid reaches its normal operating temperature ( 70 - 80 ° C ( 158 - 176 ° F )), check the A/T fluid level by refering to the diagram. 13. When the transmission fluid is less than the specified level, add transmission fluid. When the transmission fluid is greater than the specified level, drain the excess fluid through the drain plug to adjust the transmission fluid to the specified level. 14. Firmly insert the dipstick into the oil filler tube. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement > Page 1065 Fluid - A/T: Service and Repair A/T Fluid Check A/T FLUID CHECK 1. Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 - 80 °C (158 - 176 °F)]. NOTE: The A/T fluid temperature is measured with scan tool MB991502 (MUT-II). NOTE. If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 - 80'C (158 176 OF)], check the A/T fluid level by referring to the left diagram. 2. Park the vehicle on a level surface. 3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then move the selector lever to the "N" position. 4. After wiping off any dirt around the dipstick, remove the dipstick and check the condition of the A/T fluid. NOTE: If the A/T fluid smells as if it is burnt, it means that the A/T fluid has been contaminated by fine particles from the bushings and friction materials, A transaxle overhaul and cooler line flushing may be necessary. 5. Check that the A/T fluid level is at the "HOT" mark on the dipstick. If the A/T fluid level is less than this, add DIAMOND ATF SIP III or equivalent A/T fluid until the level reaches the "HOT" mark. NOTE: If the A/T fluid level is too low, the oil pump will draw in air along with the A/T fluid, which will cause bubbles to form. If the A/T fluid level is too high, rotating components inside the transaxle will chum the fluid and air into a foamy liquid. Both conditions (level too low or too high) will cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. NOTE: In either case, air bubbles can interfere with normal valve, clutch, and brake operation. Also, foaming can cause A/T fluid to escape from the transaxle vent where it may be mistaken for a leak. 6. Securely insert the dipstick. NOTE: The A/T fluid should always be replaced under the following conditions: When troubleshooting the transaxle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement > Page 1066 - When overhauling the transaxle. - When the A/T fluid is noticeably dirty or burnt (driving under severe conditions). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications Manual Transmission .......................................................................................................................... SAE 75W-90 or 75W/85W API Classification GL-4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Transaxle Oil Level Check Fluid - M/T: Service and Repair Transaxle Oil Level Check TRANSAXLE OIL LEVEL CHECK 1. Remove the filler plug. 2. Check that the oil level is up to the lower edge of the filler plug hole. 3. Check that the oil is not noticeably dirty. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Transaxle Oil Level Check > Page 1072 Fluid - M/T: Service and Repair Transaxle Oil Replacement TRANSAXLE OIL REPLACEMENT 1. Remove the filler plug. 2. Remove the drain plug and drain the oil. 3. Tighten the drain plug to the specified torque. Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.) 4. Fill with gear oil SAE 75W - 90W or 75W - 85W conforming to API classification until the level comes to the lower portion of filler plug hole. Quantity: 2.2 dm3 (2.3 quarts) 2.8 dm3 (3.0 quarts) 5. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Engine Oil: Pressure, Vacuum and Temperature Specifications Oil pressure at curb idle speed kPa (psi) [Oil temperature is 75 to 90 °C (167 to 194 °F)]; 78 kPa (11.4 psi) or more Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1077 Engine Oil: Capacity Specifications Oil Filter ............................................................................................................................................... ..................................................................... 0.32 Qt Total Capacity ...................................................................................................................................... ....................................................................... 4.5 Qt Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1078 Engine Oil: Fluid Type Specifications Engine Oil Viscosity Below 100°F (38°C) ............................................................................................................................. ................................................... 5W-30 (Preferred) Above 0°F (-18°C) ............................................................................................................................... .................................................................... 10W-30 CAUTION: Never use non detergent or straight mineral oil. Use only engine oils displaying the ILSAC certification mark ("Starburst" symbol) on the container. If these oils are not available, an API classification SJ EC or SJ/CD EC can be used. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1079 Engine Oil: Testing and Inspection ENGINE OIL CHECK 1. Pull out the oil dipstick slowly and check that the oil level is within the marks on the oil dipstick. 2. Check that the oil is not excessively dirty, that there is no coolant or gasoline mixed in, and that it has sufficient viscosity. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1084 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1085 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1086 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1087 Power Steering Fluid: Technical Service Bulletins A/T, Power Steering - ATF+4 Fluid Usage NUMBER: 21-003-02 GROUP: Transmission DATE: Jul. 29, 2002 SUBJECT: ATF+4 Usage OVERVIEW: This bulletin provides information about ATF+4 usage in ST22 models. MODELS: 2001 - 2003 (ST) Sebring/Stratus Coupe DISCUSSION: ATF+4 (type 9602) is approved for use in Sebring/Stratus Coupe power steering and automatic transaxles. The fluid is fully compatible in power steering systems and no additional maintenance information is required. When using ATF+4 in automatic transaxles, the following information is required for proper service and maintenance. SCHEDULED MAINTENANCE When using ATF+4 as a complete fill in Sebring/Stratus Coupe models, the maintenance for schedule A is changed to a 60,000 mile fluid replacement interval. Schedule B remains the same as listed in the owners manual. The owner should be notified about this schedule change when ATF+4 is used as a complete fill. NOTE: USING ATF+4 FOR TOP OFF WILL NOT CHANGE THE ORIGINAL CHARACTERISTICS OF THE FACTORY FILL OR ORIGINAL MAINTENANCE SCHEDULE. GENERAL SERVICE FILL ATF+4 is fully compatible for top off or for any transaxle service procedures that would require fluid fill or fluid replacement. Special considerations are required if a new torque converter is installed. TORQUE CONVERTER REPLACEMENT If a new torque converter is installed, ATF+4 can be used however, green torque converter shudder MAY be experienced. If green torque converter shudder is experienced, it will be eliminated over time as the torque converter clutches wear or burnish in. If shudder occurs, the vehicle can be driven (in torque converter partial lockup) until the condition is eliminated. If customer concerns arise due to green torque converter shudder use the following procedure. NOTE: TO ELIMINATE ANY CONCERNS OF GREEN TORQUE CONVERTER SHUDDER, THE TRANSAXLE CAN BE FILLED WITH DIAMOND SPIII FLUID PN 05073942AA DURING THE INITIAL FILL. 1. Drain and refill the transaxle with a minimum of 80% Diamond SPIII Transmission Fluid pn 05073942AA. 2. Warm the transaxle (by driving) to a minimum of 40 degrees C (104 degrees F). 3. Drive the vehicle for 50 kilometers (30 miles) in a speed range as shown to keep the transaxle torque converter in partial lock up. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1088 PARTS REQUIRED POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid ........................................................................................................................... ........................................................ 0.9dm3 (0.95qt) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1091 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1092 Power Steering Fluid: Testing and Inspection FLUID LEVEL CHECK 1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). 2. With the engine running, turn the wheel all the way to the left and right several times. 3. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm (0.2 inch) or more, air bleeding should be done. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1093 Power Steering Fluid: Service and Repair FLUID REPLACEMENT 1. Raise and support the front wheels. 2. Disconnect the return hose connection. 3. Connect a vinyl hose to the return hose, and drain the fluid into a container. CAUTION: Be careful not to position the high-tension cable near the fuel rail. 4. Disconnect the high-tension cable. 5. While operating the starting motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid. 6. Connect the return hoses securely, and then secure with the clip. 7. Fill the oil reservoir with Automatic transmission fluid DEXRON 1103 to the lower position of the filler, and then bleed the air. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity Refrigerant Capacity 14.6 - 15.3 oz (415 - 435 g) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1098 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. .......................................................................... 134a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1099 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1100 http://www.macsw.org/ Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1101 Refrigerant: Testing and Inspection REFRIGERANT LEVEL TEST Use the refrigerant recovery station to remove all of the refrigerant, and then calculate the amount of the refrigerant and charge it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacities Refrigerant Oil Capacities 4.1 fl oz (120 cm3) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1106 Refrigerant Oil: Fluid Type Specifications SUN PAG 56 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1107 Refrigerant Oil: Service and Repair REFILLING OF OIL IN THE A/C SYSTEM Too little oil will provide inadequate compressor lubrication and cause a. compressor failure. Too much oil will increase discharge air temperature. When a compressor is installed at the factory, it contains 120 cu. cm (4.1 floz) of refrigerant oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant. Some of this oil will be trapped and retained in various parts of the system. When the following system components are changed, it is necessary to add oil to the system to replace the oil being removed with the component. Compressor oil: SUN PAG 56 Quantity: - Evaporator: 60 cu.cm (2.0 floz) - Condenser: 15 cu.cm (0.5 floz) - Suction hose: 10 cu.cm (0.3 floz) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair CAUTION: Use only brake fluid DOT 3 or DOT 4. Never mix the specified brake fluid with other fluid as it will influence the braking performance significantly. MASTER CYLINDER BLEEDING The master cylinder has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.) 1. Fill the reserve tank with brake fluid. 2. Keep the brake pedal depressed. 3. Have another person cover the master cylinder outlet with a finger. 4. With the outlet still closed, release the brake pedal. 5. Repeat steps 2 - 4 three or four times to fill the inside of the master cylinder with brake fluid. BRAKE LINE BLEEDING CAUTION: For vehicles equipped with ABS, be sure to filter/strain the brake fluid being added to the master cylinder reservoir tank. Debris may damage the hydraulic unit. Start the engine and bleed the air in the sequence shown in the figure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-12-2 Junction Block (Top) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1118 8w-12-3 Junction Block (Bottom) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1119 Circuit Breakers Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Centralized Junction Fuse: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Centralized Junction > Page 1124 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Centralized Junction > Page 1125 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Centralized Junction > Page 1126 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Centralized Junction > Page 1127 Fuse: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Centralized Junction > Page 1128 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Centralized Junction > Page 1129 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1132 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1133 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1134 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1135 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1136 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1137 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1138 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1139 Fuse: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1140 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1141 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1142 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1143 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1144 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1147 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Centralized Junction Fuse: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Centralized Junction > Page 1155 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Centralized Junction > Page 1156 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Centralized Junction > Page 1157 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Centralized Junction > Page 1158 Fuse: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Centralized Junction > Page 1159 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Centralized Junction > Page 1160 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Centralized Junction Fuse Block: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Centralized Junction > Page 1165 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Centralized Junction > Page 1166 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Centralized Junction > Page 1167 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Centralized Junction > Page 1168 Fuse Block: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Centralized Junction > Page 1169 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Centralized Junction > Page 1170 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 Fuse Block: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 Fuse Block: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Centralized Junction Fuse Block: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 1198 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 1199 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 1200 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 1201 Fuse Block: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 1202 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 1203 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations Fusible Link: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1207 Centralized Junction/Fusible Link And Fuse Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1208 Centralized Junction/Fusible Link And Fuse Part 2 Fusible Links 1-25 (Relay Box In Engine Compartment) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1209 Fusible Link 26 (Connected Directly To Battery Positive Terminal) , Fusible Link 27 (Connected In Front Of The Fusible Link Box) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1210 Passenger Compartment (In Junction Block) Part 1 Passenger Compartment (In Junction Block) Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1211 Fuses 1 - 24 (In Junction Block) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1212 Fusible Link: Application and ID Centralized Junction/Fusible Link And Fuse Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1213 Centralized Junction/Fusible Link And Fuse Part 2 Fusible Links 1-25 (Relay Box In Engine Compartment) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1214 Fusible Link 26 (Connected Directly To Battery Positive Terminal) , Fusible Link 27 (Connected In Front Of The Fusible Link Box) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1215 Passenger Compartment (In Junction Block) Part 1 Passenger Compartment (In Junction Block) Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 1216 Fuses 1 - 24 (In Junction Block) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Centralized Junction Relay Box: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Centralized Junction > Page 1221 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Centralized Junction > Page 1222 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Centralized Junction > Page 1223 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Centralized Junction > Page 1224 Relay Box: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Centralized Junction > Page 1225 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Centralized Junction > Page 1226 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Box: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 Relay Box: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Relay Box: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Centralized Junction Relay Box: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Centralized Junction > Page 1254 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Centralized Junction > Page 1255 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Centralized Junction > Page 1256 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Centralized Junction > Page 1257 Relay Box: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Centralized Junction > Page 1258 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Centralized Junction > Page 1259 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation TROUBLE CODE DIAGNOSIS Among the on-board diagnostic items, a Malfunction Indicator Lamp (SERVICE ENGINE SOON or Check Engine Lamp) illuminates to notify the driver of an emission control malfunction. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Application and ID Oil Change Reminder Lamp: Application and ID This vehicle does not have an Oil Change Reminder Light. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information Vehicle Lifting: Technician Safety Information STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1272 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1273 Vehicle Lifting: Vehicle Damage Warnings STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1274 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 1275 Vehicle Lifting: Service and Repair LIFTING, JACKING SUPPORT LOCATION FLOOR JACK CAUTION: Never support any point other than the specified one, or it will be deformed. - For lifting, put rubber or similar material between the side sill and rigid rack, or the side sill area will be damaged. POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations. CAUTION: When service procedures require removing rear suspension, fuel tank and spare tire, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravity changes. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications Tire Size 2.4L, 3.0L P205/60 R16 91H (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L P215/50 R17 90H (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Tread depth of tire Minimum 0.06 in. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Inflation Tires: Testing and Inspection Tire Inflation TIRE INFLATION PRESSURE CHECK NOTE: For information on the inflation pressure, refer to the label attached to the center pillar on the driver's side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Inflation > Page 1281 Tires: Testing and Inspection Tread Wear Indicators TIRE WEAR CHECK Measure the tread depth of the tires. Minimum limit: 1.6 mm (0.06 inch) If the remaining tread depth is less than the minimum limit, replace the tire. NOTE: When the tread depth of the tires is reduced to 1.6 mm (0.06 inch) or less, wear indicators will appear. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 1286 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1287 Wheels: Specifications Wheel Type 2.4L, 3.0L Steel type, aluminum type (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L Aluminum type (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Size 2.4L, 3.0L 16 x 6JJ (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L 17 x 6.5JJ (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Amount of wheel offset 2.4L, 3.0L 1.8 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L 1.8 in. (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Pitch circle diameter (PCD) 2.4L, 3.0L 4.50 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L 4.50 in. (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Spare Wheel Type 2.4L, 3.0L Steel type (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Size 2.4L, 3.0L 16 x 4T (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Amount of wheel offset 2.4L, 3.0L 1.8 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Pitch circle diameter (PCD) 2.4L, 3.0L 4.50 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1288 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Wheel Runout (Radial runout) Steel Wheel 0.05 in. or less Aluminum wheel 0.04 in. or less Wheel Runout (Lateral runout) Steel Wheel 0.05 in. or less Aluminum wheel 0.04 in. or less Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1289 Wheels: Service and Repair WHEEL AND TIRE INSTALLATION SERVICE POINT Tighten the wheel nut to the specified torque. Tightening torque: 98 ± 10 Nm (73 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Nut ............................................................................................................................................... .............................. 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 1294 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front Wheel Bearing Breakaway Torque Check INSPECTION WHEEL BEARING BREAKAWAY TORQUE CHECK 1. Install the special tools MB990998 and MB990326 to the front hub assembly and tighten the nut to the specified torque. Tightening torque: 226 ± 29 Nm (167 ± 21 ft. lbs.) 2. Measure the wheel bearing breakaway torque with special tools. Limit: 1.0 Nm (9 inch lbs.) or less 3. Wheel bearing breakaway torque must be under the limit value and there should be no roughness when rotating the hub. Wheel Bearing End Play Check WHEEL BEARING END PLAY CHECK 1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the end play while moving the hub in the axial direction. Limit: 0.05 mm (0.002 inch) 4. If end play exceeds the limit, replace the front hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 1297 Wheel Bearing: Testing and Inspection Rear Rear Hub Rotary-Sliding Resistance Check REAR HUB ROTARY-SLIDING RESISTANCE CHECK 1. For vehicles with rear disc brakes, remove the Caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. After turning the hub a few times to seat the bearing, wind a rope around the hub bolt and turn the hub by pulling at a 90 degree angle with a spring balance. Measure to determine whether or not the rotary-sliding resistance of the rear hub is at the limit value. Limit:...............18 Nm (13 ft. lbs.) 4. If the rotary-sliding resistance exceeds the limit value, replace the rear hub assembly. Wheel Bearing End Play Check 1. For vehicles with rear disc brakes, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. Check the bearing's end play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is end play. Limit:................0.05 mm (0.002 inch) 4. If the play exceeds the limit value, replace the rear hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Ball Joint Pinch Bolt ............................................................................................................................. .................................. 108 ± 10 Nm (80 ± 7 ft. lbs.) Wheel Hub Mounting Bolts ........................................................................................................................................................... 88 ± Nm (65 ± 7 ft. lbs.) Axle Nut ........................................................................................................ ..................................................................... 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Axle Hub Assembly - Front / REMOVAL AND INSTALLATION CAUTION: For vehicles with ABS, be careful when handling the projection at the tip of the speed sensor so as not to damage it by striking against other parts. The front hub assembly should not be dissembled. When removing the front hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the front hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play. REMOVAL SERVICE POINTS << A >> DRIVE SHAFT NUT REMOVAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1303 CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when drive shaft nut is loosened. << B >> TIE ROD END DISCONNECTION CAUTION Do not remove nut from ball joint but loosen it and use special tools instead to avoid possible damage to ball joint threads. Hang special tools with ropes to prevent them from failing. INSTALLATION SERVICE POINT >> A << DRIVE SHAFT NUT INSTALLATION CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when castle nut is loosened. 1. Direct the flat side of a washer to a drive shaft nut to install. 2. Tighten driveshaft nut fully with special tools. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1304 Wheel Hub: Service and Repair Rear Axle Hub Assembly - Rear / REMOVAL AND INSTALLATION REMOVAL SERVICE POINTS << A >> CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1305 << B > ABS ROTOR REMOVAL << C >> BACKING PLATE REMOVAL Remove the backing plate and suspend it. INSTALLATION SERVICE POINT >> A << ABS ROTOR INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 1310 Wheel Fastener: Specifications Wheel Nut 73 +/- 7 ft. lbs. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front FRONT / HUB BOLT REPLACEMENT Required Special Tools: MB990767: End Yoke Holder MB991618: Hub Bolt Remover 1. Remove the caliper assembly and suspend it with wire so that it does not fall. 2. Remove the brake disc. 3. Use the special tools MB990767 and MB99161 to remove the hub bolts. 4. Install the plain washer to the new hub bolt, and install the bolt with a nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1313 Wheel Fastener: Service and Repair Rear REAR / HUB BOLT REPLACEMENT Required Special Tools: MB990767: End Yoke Holder MB991618: Hub Bolt Remover 1. For vehicles with rear disc brakes, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brake, remove the brake drum. 3. Pull the hub bolt out using special tools MB990767 and MB991618. NOTE: For vehicles with drum brakes, the hub bolts should be removed near the retainer spring installation position in order to maintain enough clearance for removal. 4. Install the plain washer to the new hub bolt, and install the bolt with a nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information Towing Information: Technician Safety Information STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1318 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1319 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1320 Towing Information: Vehicle Damage Warnings STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1321 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 1322 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Page 1323 Towing Information: Service and Repair WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP CAUTION: This vehicle cannot be towed by a wrecker using sling- type equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equipment. The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible. REAR TOWING PICKUP CAUTION: This vehicle cannot be towed by a wrecker using sling-type equipment, otherwise the lower may suffer deformation. If this vehicle is towed, use a wheel lift or flat bed equipment. - Do not use the steering column lock to secure the front wheel for towing. - Make sure the transaxle is in Neutral if vehicle will have drive wheels on the ground. - If these limits cannot be met, the front wheels must be placed on a tow dolly. Automatic transmission vehicle may be towed on the front wheels at speeds not to exceed 50 km/h (30 mph) for distances not to exceed 30 km (18 miles). TOWING WHEN KEYS ARE NOT AVAILABLE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service Precautions > Page 1324 When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front, provided the parking brake is released. If not released, the rear wheels should be placed on a tow dolly. SAFETY PRECAUTIONS The following precautions should be taken when towing the vehicle: 1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER. 2. Any loose or protruding parts or damaged vehicle such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle. 3. Operator should retrain from going under a vehicle if is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands. 4. Never allow passengers to ride in a towed vehicle. 5. state and local rules and regulations must be followed when towing a vehicle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information Vehicle Lifting: Technician Safety Information STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1329 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1330 Vehicle Lifting: Vehicle Damage Warnings STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 1331 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service Precautions > Page 1332 Vehicle Lifting: Service and Repair LIFTING, JACKING SUPPORT LOCATION FLOOR JACK CAUTION: Never support any point other than the specified one, or it will be deformed. - For lifting, put rubber or similar material between the side sill and rigid rack, or the side sill area will be damaged. POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations. CAUTION: When service procedures require removing rear suspension, fuel tank and spare tire, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravity changes. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressure ........................................................................................................................ ........................................................... (250 - 400 rpm) Standard Value .................................................................................................................................... ................................................ 1,275 kPa (185 psi) Limit (Minimum) ................................................................................................................................... .......................................... 959 kPa (139 psi) Compression pressure difference of all cylinder Limit ..................................................................................................................................................... ............................................... 98 kPa (14 psi) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1338 Compression Check: Testing and Inspection COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights, and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crankshaft position sensor connector. NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel injection. WARNING: Keep your distance from the spark plug hole when cranking. Oil, fuel, etc., may spray out from the spark plug hole and may cause serious injury. 5 Cover the spark plug hole with a shop towel etc., during cranking. After the engine has been cranked, check for foreign material adhering to the shop towel. 6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 - 400 rpm): 1,275 kPa (185 psi) Minimum limit (at engine speed of 250 - 400 rpm): 959 kPa (139 psi) 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: 98 kPa (14 psi) 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 to 8. 1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/ or cylinder inner surface. 2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crankshaft position sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the scan tool to erase the diagnostic trouble codes. NOTE: This will erase the diagnostic trouble code resulting from the crankshaft position sensor connector being disconnected. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket attaching bolt ............................................................................................................................................... 88 ± 10 Nm (65 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft position sensing cylinder attaching bolt ....................................................................................................................... 21 ± 4 Nm (16 ± 3 ft. lbs.) Camshaft position sensor support attaching bolt ..................................................................................................................... 14 ± 1 Nm (117 ± 13 in. lbs.) Camshaft cam height Intake Standard Value .................................................................................................................................... ....................................... 37.39 mm (1.472 in.) Limit (Minimum) ......................................................... ............................................................................................................... 36.89 mm (1.452 in.) Exhaust M/T Standard Value .................................................................................................................................... ....................................... 37.14 mm (1.462 in.) Limit (Minimum) ......................................................... ............................................................................................................... 36.64 mm (1.443 in.) A/T Standard Value..................................................................................................................................... ....................................... 36.83 mm (1.450 in.) Limit (Minimum) ......................................................... ............................................................................................................... 36.33 mm (1.430 in.) Camshaft journal outside diameter ...................................................................................................... ........................................................... 45 mm (18 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1346 Camshaft: Diagrams CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1347 Camshaft: Service and Repair CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Required Special Tools: ^ MB990767: End Yoke Holder ^ MB998713: Crankshaft Oil Seal Installer ^ MD998443: Auto-lash Adjuster Holder ^ MD998719: Crankshaft Pulley Holder Pin REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1348 1. Use special tools MB990767 and MD998719 to loosen the camshaft sprocket securing bolt. 2. Remove the camshaft sprocket. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1349 5 Make sure that the notch in the end of the rocker arm shaft is facing the direction shown. >>B<< CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use special tool MD998713 to press-fit the camshaft oil seal. >>C<< CAMSHAFT SPROCKET INSTALLATION 1. Install the camshaft sprocket. 2. Use special tools MB990767 and MD998719 to tighten the camshaft sprocket securing bolt to the specified torque. Tightening torque: 88 ± 10 Nm (65 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection LASH ADJUSTER CHECK If an abnormal noise (chattering noise) suspected to be caused by malfunction of the lash adjuster is produced immediately after starting the engine and does not disappear, perform the following check. NOTE: An abnormal noise due to malfunction of the lash adjuster is produced immediately after starting the engine and changes with the engine speed, irrespective of the engine load. If, the abnormal noise is not produced immediately after starting the engine or does not change with the engine speed, or it changes with file engine load, the lash adjuster is not the cause for the abnormal noise. NOTE: When the lash adjuster is malfunctioning, the abnormal noise is rarely eliminated by continuing the warming-up of the engine at idle speed. However, the abnormal noise may disappear only when seizure is caused by oil sludge in the engine whose oil is not maintained properly. 1. Start the engine. 2. Check if the abnormal noise produced immediately after starting the engine, changes with the change in the engine speed. If the abnormal noise is not produced immediately after starting the engine or it does not change with the engine speed, the lash adjuster is not the cause for the noise. Therefore, investigate other causes. The abnormal noise is probably caused by some other parts than the engine proper if it does not change with the engine speed. (In this case, the lash adjuster is in good condition.) 3. With the engine idling, change the engine load (shift from N to D range, for example) to make sure that there is no change in the level of abnormal noise. If there is a change in the level of abnormal noise, suspect a tapping noise due to worn crankshaft bearing or connecting rod bearing. (In this case, the lash adjuster is in good condition.) 4. After completion of warm-up, run the engine at idle to check for abnormal noise. If the noise is reduced or disappears, clean the lash adjuster. As it is suspected that the noise is due to seizure of the lash adjuster. If there is no change in the level of the abnormal noise, proceed to step 5. 5 Run the engine to bleed the lash adjuster system. 6. If the abnormal noise does not disappear after air bleeding operation, clean the lash adjuster. Bleeding lash adjuster system NOTE: Parking the vehicle on a grade for a long time may decrease oil in the lash adjuster, causing air to enter the high pressure chamber when starting the engine. NOTE: After parking for many hours, oil may run out from the oil passage and take time before oil is supplied to the lash adjuster, causing air to enter the high pressure chamber. NOTE: In the above cases, abnormal noise can be eliminated by bleeding the lash adjuster system. 1. Check engine oil and add or change oil if required. NOTE: If the engine oil level is low, air is sucked from the oil screen, causing air to enter the oil passage. NOTE: If the engine oil level is higher than specification, oil may be stirred by the crankshaft, causing oil to be mixed with a large quantity of air. NOTE: If oil is deteriorated, air is not easily separated from oil, increasing the quantity of air contained in oil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1353 NOTE: If air mixed with oil enters the high pressure chamber inside the lash adjuster from the above causes, air in the high pressure chamber is compressed excessively while the valve is opened, resulting in an abnormal noise when the valve closes. This is the same phenomenon as that observed when the valve clearance has become excessive. The lash adjuster can resume normal function when air entered the lash adjuster is removed. 2. Idle the engine for one to three minutes to warm it up. 3. Repeat the operation pattern, shown in left figure, at no load to check for abnormal noise. (Usually the abnormal noise is eliminated after repetition of the operation 10 to 30 times. If, however, no change is observed in the level of abnormal noise after repeating the operation more than 30 times, suspect that the abnormal noise is due to some other factors.) 4. After elimination of abnormal noise, repeat the operation shown in left figure five more times. 5 Run the engine at idle for one to three minutes to make sure that the abnormal noise has been eliminated. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker arm and shaft assembly attaching bolt ............................................................................................................................ 31 ± 3 Nm (23 ± 2 ft. lbs.) Rocker arms and camshaft Rocker cover bolt ................................................................................................................................. ............................... 3.5 ± 0.5 Nm (30 ± 4 in. lbs.) Rocker arm shaft bolt ............................................ ................................................................................................................... 31 ± 3 Nm (23 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting rod cap nut ............................................................................................................................................. 20 ± 2Nm (14 ± 1 ft. lbs.) + 90° to 94° Connecting rod big end side clearance Standard Value ............................................................................................................................................................. 0.10 - 0.25 mm (0.004 - 0.009 in.) Limit .............................................................................................. ....................................................................................................... 0.4 mm (0.015 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft pin oil clearance Standard Value ......................................................................................................................................................... 0.02 - 0.05 mm (0.0008 - 0.0019 in.) Limit .......................................................................................... ........................................................................................................... 0.1 mm (0.003 in.) Crankshaft and cylinder block Crankshaft end play Standard Value ............................................................................................................................................................. 0.05 - 0.25 mm (0.002 - 0.009 in.) Limit .............................................................................................. ..................................................................................................... 0.40 mm (0.015 in.) Crankshaft journal outside diameter Standard Value .................................................................................................................................... ................................................. 57.0 mm (2.24 in.) Crankshaft pin outside diameter Standard Value .................................................................................................................................... ................................................. 45.0 mm (1.77 in.) Crankshaft journal oil clearance Standard Value .......................................................................................................................................................... 0.02- 0.04 mm (0.0008 - 0.0015 in.) Limit 0.1 mm (0.003 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft pulley attaching bolt .................................................................................................................................................... 25 ± 4 Nm (18 ± 4ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston outside diameter Standard Value .................................................................................................................................... ................................................. 86.5 mm (3.40 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston pin outside diameter Standard Value .................................................................................................................................... ................................................. 22.0 mm (0.87 in.) Piston pin press-in load N (lbs.) (Room temperature) Standard Value ........................................................................................................................................................ 7,350 - 17,200 N (1,653 - 3,866 lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston ring side clearance No.1 Standard Value ................................................................................................................................................... 0.02 0.06 mm (0.0008 - 0.0023 in.) Value ................................................................................................... ........................................................................................... 0.1 mm (0.003 in.) No.2. Standard Value ................................................................................................................................................ 0.02 0.06 mm (0.0012 - 0.0023 in.) Limit ..................................................................................................................................................... ............................................................. 0.1(0.003) Piston ring end gap No.1 Standard Value ....................................................................................................................................................... 0.25 - 0.35 mm (0.010 - 0.013 in.) Limit .............................................................................................. ................................................................................................... 0.8 mm (0.03 in.) No.2 Standard Value ....................................................................................................................................................... 0.40 - 0.55 mm (0.016 - 0.021 in.) Limit .............................................................................................. ................................................................................................... 0.8 mm (0.03 in.) Oil ring side rail Standard Value ....................................................................................................................................................... 0.10 - 0.40 mm (0.004 - 0.015 in.) Limit .............................................................................................. ................................................................................................... 1.0 mm (0.03 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1380 Fuel Pressure Release: Service and Repair FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the instrument panel side cover (driver's side). 2. Disconnect the fuel pump relay (2). 3. Start the engine and let it run until it stops naturally. Turn the ignition switch to the "LOCK" (OFF) position. 4. Connect the fuel pump relay (2). 5. Install the instrument panel side cover (driver's side). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker arm and shaft assembly attaching bolt ............................................................................................................................ 31 ± 3 Nm (23 ± 2 ft. lbs.) Rocker arms and camshaft Rocker cover bolt ................................................................................................................................. ............................... 3.5 ± 0.5 Nm (30 ± 4 in. lbs.) Rocker arm shaft bolt ............................................ ................................................................................................................... 31 ± 3 Nm (23 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve timing Intake valve Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1387 Standard Value ............................................................................................................................................... 34.60 - 34.63 mm (1.3623 - 1.3633 in.) Exhaust oversize rework dimensions of valve seat hole 0.3 oversize diameter Standard Value ............................................................................................................................................... 31.80 31.83 mm (1.2520 - 1.2531 in.) 0.6 oversize diameter Standard Value ...................................................................................................................................................... 32.10 - 32.13 (1.2638 - 1.2650 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Engine mount bracket attaching nut ........................................................................................................................................... 86 ± 12 Nm (64 ± 8 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications SERVICE SPECIFICATION FASTENER TIGHTENING SPECIFICATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Diagrams > Engine Mounting Engine Mount: Diagrams Engine Mounting ENGINE MOUNTING <2.4L ENGINE> CAUTION: Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Diagrams > Engine Mounting > Page 1400 Engine Mount: Diagrams Engine Roll Stopper and Center Member ENGINE ROLL STOPPER AND CENTERMEMBER CAUTION: Mounting indications marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Diagrams > Engine Mounting > Page 1401 loading the full weight of the engine on the vehicle body. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Diagrams > Page 1402 Engine Mount: Description and Operation POWER PLANT MOUNT GENERAL DESCRIPTION The engine-transaxle mount is of an inertial axis supporting type whose excellent features have already been proven in many Mitsubishi vehicles. The inertial axis supporting type mount supports the front upper part of the engine at the front and the rear upper part of the transaxle at the rear. This arrangement effectively suppresses the engine vibration. ENGINE MOUNT CONSTRUCTION DIAGRAM <2.4 L ENGINE> <3.0L ENGINE> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mounts Engine Mount: Service and Repair Engine Mounts ENGINE MOUNTING REMOVAL AND INSTALLATION CAUTION: Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. <2.4L ENGINE> INSTALLATION SERVICE POINT >>A<< ENGINE MOUNT STOPPER INSTALLATION Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mounts > Page 1405 INSPECTION ^ Check the insulators for cracks, separation or deformation. ^ Check the front insulator stoppers for deformation. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mounts > Page 1406 Engine Mount: Service and Repair Engine Roll Stopper ENGINE ROLL STOPPER AND CENTERMEMBER REMOVAL AND INSTALLATION CAUTION: Mounting indications marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mounts > Page 1407 INSTALLATION SERVICE POINT >>A<< FRONT ROLL STOPPER INSTALLATION Install so that the hole in the front roll stopper is facing towards the front of the vehicle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 1408 Engine Mount: Tools and Equipment SPECIAL TOOLS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure at idle ................................................................................................................................................... .................................................... 29 (4.2) or more at 3,500 rpm ......................................................... .............................................................................................................................. 294 - 686 (43 100) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1413 Engine Oil Pressure: Testing and Inspection OIL PRESSURE CHECK Required Special Tool: ^ MD998054: Oil Pressure Switch Wrench 1. Check engine oil quantity. 2. Remove the oil pressure switch terminal. CAUTION: Since sealant is applied to the thread of the oil pressure switch, take care not to damage the oil pressure switch when removing it. 3. Use special tool MD998054 to remove the oil pressure switch. 4. Install the oil pressure gauge. NOTE: Use a 1/8 pipe thread adapter. 5 Run the engine to warm it. 6. After the engine has been warmed up, check that oil pressure is within the standard value. Standard value: At idle: 29 kPa (4.2 psi) or more At 3,500 rpm: 294 - 686 kPa (43 - 100 psi) 7. Remove the oil pressure gauge. 8. Apply the specified sealant 3M(tm) MD Part number 8672 or equivalent to thread of the oil pressure switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1414 CAUTION: Do not start the engine within one hour after the engine oil pressure switch has been installed. 9. Use special tool MD998054 to tighten the oil pressure switch to the specified torque. Tightening torque: <2.4L ENGINE> 19 ± 3 Nm (14 ± 2 ft. lbs.) <3.0L ENGINE> 10 ± 2 Nm (87 ± 17 in. lbs.) 10. Install the oil pressure switch terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil dipstick guide attaching bolt .............................................................................................................................................. 14 ± 1 Nm (117 ± 13 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Drain plug ............................................................................................................................................ ........................................ 39 ± 5 Nm (29 ± 4 ft. lbs.) Plug ................................................................... ........................................................................................................................... 24 ± 3 Nm (17 ± 3 ft. lbs.) Relief plug .................................................................................................................................... ................................................. 44 ± 5 Nm (33 ± 4ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Engine Oil: Pressure, Vacuum and Temperature Specifications Oil pressure at curb idle speed kPa (psi) [Oil temperature is 75 to 90 °C (167 to 194 °F)]; 78 kPa (11.4 psi) or more Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1425 Engine Oil: Capacity Specifications Oil Filter ............................................................................................................................................... ..................................................................... 0.32 Qt Total Capacity ...................................................................................................................................... ....................................................................... 4.5 Qt Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1426 Engine Oil: Fluid Type Specifications Engine Oil Viscosity Below 100°F (38°C) ............................................................................................................................. ................................................... 5W-30 (Preferred) Above 0°F (-18°C) ............................................................................................................................... .................................................................... 10W-30 CAUTION: Never use non detergent or straight mineral oil. Use only engine oils displaying the ILSAC certification mark ("Starburst" symbol) on the container. If these oils are not available, an API classification SJ EC or SJ/CD EC can be used. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1427 Engine Oil: Testing and Inspection ENGINE OIL CHECK 1. Pull out the oil dipstick slowly and check that the oil level is within the marks on the oil dipstick. 2. Check that the oil is not excessively dirty, that there is no coolant or gasoline mixed in, and that it has sufficient viscosity. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > ENGINE LUBRICATION - WARNING! INCORRECT OIL FILTER USE Oil Filter: Technical Service Bulletins ENGINE LUBRICATION - WARNING! INCORRECT OIL FILTER USE NUMBER: 09-011-04 GROUP: Engine DATE: April 27, 2004 SUBJECT: Incorrect Oil Filter Usage OVERVIEW: This bulletin describes proper oil filter usage for the two different 2.4L engines. MODELS: 2001 - 2005 JR Sebring Convertible/Sebring Sedan/Stratus Sedan 2001 - 2005 ST Sebring/Stratus Coupe DISCUSSION: When performing scheduled maintenance, it is critical to use the correct oil filter to prevent engine damage. There may be some confusion between the two different 2.4L engines that have been used from model years 2001 through 2005. One 2.4L engine (DOHC) manufactured by Daimlerchrysler is used in the Sebring Convertible, Sebring Sedan and Stratus Sedan. The oil filter used for this engine is p/n 04105409. The second 2.4L engine (SOHC) is manufactured by Mitsubishi Motors Corporation (MMC). This engine is used in the Sebring Coupe and Stratus Coupe. The oil filter used for this engine is p/n MD360935. CAUTION: The MMC oil filter could be incorrectly installed on a DaimlerChrysler built 2.4L engine. Use of the MMC oil filter on a DaimlerChrysler built 2.4L engine will result in engine damage due to oil loss. POLICY: Information Only. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1432 Oil Filter: Specifications Oil filter part number MD360935 ............................................................................................................................................ 14 ± 2 Nm (122 ± 17 in. lbs.) Oil filter other than MITSUBISHI genuine filter ......................................................................................................................... 17 ± 2 Nm (13 ± 1 ft. lbs.) Oil filter bracket bolt ..................................................................................................................... ............................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan attaching bolt .............................................................................................................................................................. 6.9 ± 0.9 Nm (61 ± 8 in. lbs.) Oil pan drain plug .................................................................................. ........................................................................................ 39 ± 5 Nm (29 ± 4ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1436 Oil Pan: Diagrams OIL PAN Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1437 Oil Pan: Service and Repair OIL PAN REMOVAL AND INSTALLATION Required Special Tool: ^ MD998727: Oil Pan Remover REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1438 1. Remove sealant from the oil pan and cylinder block mating surfaces. 2. Degrease the sealant-coated surface and the engine mating surface. 3. Apply MITSUBISHI GENUINE PART number MD970389 or equivalent around the gasket surface of the oil pan. NOTE: The sealant should be applied in a continuous bead approximately 4 mm (0.2 in.) in diameter. CAUTION: After installing the oil pan, wait at least one hour before starting the engine. 4. Assemble the oil pan to the cylinder block within 15 minutes after applying the sealant. Be careful when installing the oil pan. The bolts indicated in the illustration have different lengths from the other bolts. >>B<< DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction shown in the illustration. INSPECTION ^ Check the oil pan for cracks. ^ Check the oil pan sealant-coated surface for damage and deformation. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure switch .............................................................................................................................. .......................................... 19 ± 3 Nm (14 ± 2ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil pressure switch .............................................................................................................................. ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1449 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1450 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1451 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1452 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1453 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1454 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1455 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1464 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1465 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Oil Pressure Warning Lamp/Indicator: Electrical Diagrams Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil pump cover bolt .............................................................................................................................. ....................................... 17 ± 1 Nm (12 ± 1 ft. lbs.) Oil pump cover screw ........................................ ....................................................................................................................... 9.8 ± 2 Nm (87 ± 17 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil screen bolt ...................................................................................................................................... ......................................... 19 ± 3 Nm (14 ± 3ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure at idle ................................................................................................................................................... .................................................... 29 (4.2) or more at 3,500 rpm ......................................................... .............................................................................................................................. 294 - 686 (43 100) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1482 Engine Oil Pressure: Testing and Inspection OIL PRESSURE CHECK Required Special Tool: ^ MD998054: Oil Pressure Switch Wrench 1. Check engine oil quantity. 2. Remove the oil pressure switch terminal. CAUTION: Since sealant is applied to the thread of the oil pressure switch, take care not to damage the oil pressure switch when removing it. 3. Use special tool MD998054 to remove the oil pressure switch. 4. Install the oil pressure gauge. NOTE: Use a 1/8 pipe thread adapter. 5 Run the engine to warm it. 6. After the engine has been warmed up, check that oil pressure is within the standard value. Standard value: At idle: 29 kPa (4.2 psi) or more At 3,500 rpm: 294 - 686 kPa (43 - 100 psi) 7. Remove the oil pressure gauge. 8. Apply the specified sealant 3M(tm) MD Part number 8672 or equivalent to thread of the oil pressure switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1483 CAUTION: Do not start the engine within one hour after the engine oil pressure switch has been installed. 9. Use special tool MD998054 to tighten the oil pressure switch to the specified torque. Tightening torque: <2.4L ENGINE> 19 ± 3 Nm (14 ± 2 ft. lbs.) <3.0L ENGINE> 10 ± 2 Nm (87 ± 17 in. lbs.) 10. Install the oil pressure switch terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Mechanical Specifications Intake Manifold: Mechanical Specifications Intake Manifold Torque Specifications FASTENER TIGHTENING SPECIFICATIONS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Mechanical Specifications > Page 1488 Service Specification SERVICE SPECIFICATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Mechanical Specifications > Page 1489 Intake Manifold: Pressure, Vacuum and Temperature Specifications Intake manifold vacuum at curb idle Limit ..................................................................................................................................................... ............................................... 60 kPa (18 psi) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Diagrams > Intake Manifold Plenum Intake Manifold: Diagrams Intake Manifold Plenum INTAKE MANIFOLD PLENUM Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Diagrams > Intake Manifold Plenum > Page 1492 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Diagrams > Intake Manifold Plenum > Page 1493 Intake Manifold: Diagrams Intake Manifold INTAKE MANIFOLD <2.4L> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Diagrams > Intake Manifold Plenum > Page 1494 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Diagrams > Page 1495 Intake Manifold: Description and Operation INTAKE SYSTEM GENERAL DESCRIPTION A radiator upper cool air intake method has been introduced. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Intake Manifold: Service and Repair Intake Manifold INTAKE MANIFOLD <2.4L> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1498 REMOVAL AND INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1499 >>A<< HIGH-PRESSURE FUEL HOSE INSTALLATION CAUTION: Be careful not to allow any engine oil to enter the fuel rail. 1. When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of new engine oil to the O-ring and then insert the high-pressure fuel hose, being careful not to damage the O-ring. 2. While turning the high-pressure fuel hose to the left and right, install it to the fuel rail. 3. Check that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the high pressure fuel hose and then re-insert it into the fuel rail and check again. INSPECTION Check the following points; replace the part if a problem is found. Intake Manifold Check 1. Check for damage or cracking of any part. 2. Check for obstruction of the negative pressure (vacuum) outlet port, and for obstruction of the water passage or gas passage. 3. Using a straight edge and feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm (0.006 in.) or less Limit: 0.20 mm (0.008 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1500 Intake Manifold: Service and Repair Intake Manifold Plenum INTAKE MANIFOLD PLENUM Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold > Page 1501 REMOVAL AND INSTALLATION INSTALLATION SERVICE POINT >>A<< INTAKE MANIFOLD PLENUM GASKET INSTALLATION Install the gasket with the protrusion in the position illustrated. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1510 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1511 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1512 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1513 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1514 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1515 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1516 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1517 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1518 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1519 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1520 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1521 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1522 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1523 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1524 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1525 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1526 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1527 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1528 Oil Pressure Warning Lamp/Indicator: Electrical Diagrams Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 1529 Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Diagrams Camshaft Oil Seal: Diagrams CAMSHAFT AND CAMSHAFT OIL SEAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Diagrams > Page 1534 Camshaft Oil Seal: Service and Repair CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Required Special Tools: ^ MB990767: End Yoke Holder ^ MB998713: Crankshaft Oil Seal Installer ^ MD998443: Auto-lash Adjuster Holder ^ MD998719: Crankshaft Pulley Holder Pin REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Diagrams > Page 1535 1. Use special tools MB990767 and MD998719 to loosen the camshaft sprocket securing bolt. 2. Remove the camshaft sprocket. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Diagrams > Page 1536 5 Make sure that the notch in the end of the rocker arm shaft is facing the direction shown. >>B<< CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use special tool MD998713 to press-fit the camshaft oil seal. >>C<< CAMSHAFT SPROCKET INSTALLATION 1. Install the camshaft sprocket. 2. Use special tools MB990767 and MD998719 to tighten the camshaft sprocket securing bolt to the specified torque. Tightening torque: 88 ± 10 Nm (65 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams Crankshaft Main Bearing Seal: Diagrams CRANKSHAFT REAR OIL SEAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 1540 Crankshaft Main Bearing Seal: Service and Repair CRANKSHAFT REAR OIL SEAL REMOVAL AND INSTALLATION Required Special Tools: ^ MB990938: Handle ^ MD998776: Crankshaft Rear Oil Seal Installer ^ MD998781: Flywheel Stopper REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Diagrams > Page 1541 Use special tool MD998781 to secure the flywheel or drive plate, and remove the bolt. INSTALLATION SERVICE POINTS >>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire inside diameter of the oil seal lip. 2. Use special tools MB990938 and MD998776 to tap in the oil seal as shown in the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Diagrams Cylinder Head Gasket: Diagrams CYLINDER HEAD GASKET Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Diagrams > Page 1545 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Diagrams > Page 1546 Cylinder Head Gasket: Service and Repair CYLINDER HEAD GASKET Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Diagrams > Page 1547 REMOVAL AND INSTALLATION Required Special Tool: ^ MB991654: Cylinder Head Bolt Wrench (12) REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Diagrams > Page 1548 Using special tool MB991654, loosen the bolts in two or three steps in the order of the numbers shown in the illustration, then remove the cylinder head assembly. INSTALLATION SERVICE POINTS >>A<< CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface. 2. Match the shapes of the cylinder head holes with their respective cylinder head gasket holes. >>B<< CYLINDER HEAD ASSEMBLY INSTALLATION 1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. Limit (A): 99.4 mm (3.91 inches) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Diagrams > Page 1549 2. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt. CAUTION: ^ Always tighten cylinder head bolts at a 90 degree angle. If it is less than 90 degree angle, the bolt will loosen. ^ If it is more than 90 degree angle, remove the head bolt and repeat the procedure from step 1. 3. Using special tool MB991654, tighten the bolts by the following procedure. >>C<< HIGH-PRESSURE FUEL HOSE INSTALLATION CAUTION: Do not allow engine oil to enter the fuel rail. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Diagrams > Page 1550 1. Apply a small amount of new engine oil to the O-ring. 2. While turning the high-pressure fuel hose to the right and left, install the fuel rail, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. 4. Re-insert the fuel rail and confirm the hose turns smoothly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams Front Crankshaft Seal: Diagrams CRANKSHAFT FRONT OIL SEAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams > Page 1554 Front Crankshaft Seal: Service and Repair CRANKSHAFT FRONT OIL SEAL REMOVAL AND INSTALLATION Required Special Tools: ^ MB991367: Special Spanner ^ MB998375: Crankshaft Front Oil Seal Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Diagrams > Page 1555 1. Apply engine oil to the entire inside diameter of the oil seal lip. 2. Use special tool MD998375 to press-fit the oil seal until it is flush with the front case. >>B<< CRANKSHAFT SPROCKET B/CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION 1. To prevent the crankshaft bolt from loosening, degrease or clean the seating surfaces of the crankshaft, crankshaft sprocket B. crankshaft sensing blade and crankshaft at the shown positions. 2. Install the crankshaft sensing blade so that they face as shown in the illustration. 3. Apply the minimum amount of engine oil to the seat surface and thread of the crankshaft bolt. 4. Use the crankshaft pulley mounting bolt to secure special tool MB991367. 5. Tighten the crankshaft sprocket bolt to the specified torque. Tightening torque: 118 ± 9 Nm (87 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure switch .............................................................................................................................. .......................................... 19 ± 3 Nm (14 ± 2ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil pressure switch .............................................................................................................................. ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket attaching bolt ............................................................................................................................................... 88 ± 10 Nm (65 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Timing Belt Timing Belt: Diagrams Timing Belt TIMING BELT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Diagrams > Timing Belt > Page 1571 Timing Belt: Diagrams Timing Belt B TIMING BELT B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Timing Belt: Service and Repair Timing Belt TIMING BELT REMOVAL AND INSTALLATION Required Special Tools: ^ MD998738: Adjusting Screw ^ MD998767: Tensioner Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 1574 1. Turn the crankshaft in the forward direction (to the right) to align the camshaft sprocket timing marks. 2. Loosen the tension pulley fixing bolt. CAUTION: If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction. 3. Move the tension pulley to the water pump side, and then remove the timing belt. INSTALLATION SERVICE POINTS >>A<< AUTO-TENSIONER INSTALLATION 1. Apply 98 - 196 N (22 - 44 lbs.) force to the pushrod of the auto-tensioner by pressing it against a metal object (such as the engine block) and measure the movement of the pushrod. Standard value: Within 1 mm (0.04 in.) A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 2. If it is outside the standard value, replace the auto-tensioner. CAUTION: Never compress the pushrod too fast, or it may be damaged. 3. Use a press or vise to gently compress the auto-tensioner pushrod until pin hole A of the pushrod and pin hole B of the tensioner cylinder are aligned. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 1575 4. When the holes are aligned, insert the set pin. NOTE: When replacing the auto-tensioner with a new part, the pin will be in the auto-tensioner. 5. Install the auto-tensioner to the engine. >>B<< TIMING BELT INSTALLATION 1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket. 2. After aligning the timing mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips) head 8 mm (0.3 in.) screwdriver. Check to be sure that the screwdriver goes in 60 mm (2.4 inches) or more. If the screwdriver will only go in 20 - 25 mm (0.8 - 1.0 in.) before striking the counterbalance shaft, turn the sprocket once, realign the timing marks and check that the screwdriver goes in 60 mm (2.4 inches) or more. The screwdriver should not be taken out until the timing belt is installed. CAUTION: If the timing belt is re-used, install so that the arrow marked on it at time of removal is pointing in the clockwise direction. 3. Install the belt to the crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order, so that there is no slackness in the belt tension. 4. Set the tension pulley so that the pin holes are at the bottom, press the tension pulley lightly against the timing belt, and then provisionally tighten the fixing bolt. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 1576 5 Adjust the timing belt tension. >>C<< TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft 1/4 of a revolution in the counterclockwise direction, turn it in the clockwise direction until the timing marks are aligned. CAUTION: When tightening the fixing bolt, make sure that the tension pulley does not turn with the bolt. 2. Loosen the tension pulley fixing bolt, and then use special tool MD998767 and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the timing belt. Timing belt tension torque: 3.5 Nm (31 in. lbs.) Tightening torque: 48 ± 6 Nm (36 ± 4 ft. lbs.) 3. Remove the set pin that has been inserted into the auto-tensioner. 4. Turn the crankshaft two revolutions clockwise so that the timing marks are aligned. After leaving it for 15 minutes, measure the amount of protrusion of the auto-tensioner. Standard value (A): 3.8 - 4.5 mm (0.15 - 0.18 in.) 5 If the amount of protrusion is outside the standard value, repeat steps (1) through (4). 6. Check again to be sure that the timing marks of each sprocket are aligned. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 1577 Timing Belt: Service and Repair Timing Belt B TIMING BELT B REMOVAL AND INSTALLATION Required Special Tool: ^ MB991367: Special Spanner REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 1578 CAUTION: If the belt is to be re-used, mark an arrow on the belt with chalk indicating the clockwise direction of rotation. INSTALLATION SERVICE POINTS >>A<< TIMING BELT B INSTALLATION 1. Ensure that crankshaft sprocket B timing marks and the counterbalance shaft sprocket timing marks are aligned. 2. Fit timing belt B over crankshaft sprocket B and the counterbalance shaft sprocket. Ensure that there is no slack in the belt. >>B<< CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION 1. To prevent the crankshaft bolt from loosening, degrease or clean the seating surfaces of the crankshaft, crankshaft sprocket B, crankshaft sensing blade and crankshaft at the shown positions. 2. Install the crankshaft sensing blade so that they face as shown in the illustration. 3. Apply the minimum amount of engine oil to the seat surface and thread of the crankshaft bolt. 4. Use the crankshaft pulley mounting bolt to secure special tool MB991367. 5 Tighten the crankshaft sprocket bolt to the specified torque. Tightening torque: 118 ± 9 Nm (87 ± 7 ft. lbs.) >>C<< TIMING BELT B TENSION ADJUSTMENT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt > Page 1579 1. Temporarily fix the timing belt B tensioner so the center of the tensioner pulley is to the left and above the center of the mounting bolt. Temporarily attach the tensioner pulley so the flange is toward the front of the engine. CAUTION: When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension of the bolt. 2. Holding the timing belt B tensioner up with your finger in the direction of the arrow, apply pressure on the timing belt so the tension side of the belt is taut. Now tighten the bolt to fix the tensioner. Tightening torque: 19 ± 3 Nm (14 ± 2 ft. lbs.) 3. To ensure that the tension is correct, depress the belt (point A) with a finger. Adjust the belt tension if it is incorrect. Standard value: 5 - 7 mm (0.2 - 0.3 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications Timing Belt Tensioner: Specifications Tensioner attaching bolt ...................................................................................................................... ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Auto-tensioner rod projection length Standard Value .................................................................................................................................... ...................................................... 12 mm (0.5 in.) Auto-tensioner rod pushed-in amount Standard Value .................................................................................................................................... ........................................ 1.0 mm (0.03 in.) or less [When pushed with a force of 98 - 196 N (22 44 lbs.)] Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing belt lower cover attaching bolt bolt, flange ........................................................................................................................................... .................................... 11 ± 1 Nm (96 ± 8 in. lbs.) bolt, washer assembled ........................................................................................................................................................ 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Timing belt upper cover attaching bolt M6 ........................................................................................................................................................ ................................... 11 ± 1 Nm (96 ± 8 in. lbs.) M8 ......................................................................... .............................................................................................................. 14 ± 1 Nm (117 ± 13 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure kPa (psi) Vacuum hose disconnected ................................................................................................................................................... 330 350 (47 - 50) at curb idle Vacuum hose connected ............................................................................................................................................... Approximately 270 (38) at curb idle Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1590 Fuel Pressure: Testing and Inspection FUEL PRESSURE TEST Required Special Tools: - MB9915Q2: Scan Tool (MUT-II) - MB991637: Fuel Pressure Gauge Set - MD998709: Adaptor Hose - MD998742: Hose Adaptor 1. Release residual pressure from the fuel line to prevent fuel spray. WARNING To prevent a fire, cover the hose connection with shop towels to prevent splashing of fuel that could be caused by Some residual pressure in the fuel pipe line. 2. Disconnect the high-pressure fuel hose at the fuel rail side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1591 3. Assemble the fuel pressure measurement tools as follows. 1. Rempve the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Place a suitable O-ring or gasket on assembled special tools MD998709 and MD998742 and install the fuel pressure gauge. 3. Install the assembled fuel pressure measurement tools between the fuel rail and high-pressure fuel hose. 1. Remove the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Install special tool MB991637 (fuel pressure gauge set) to assembled special tools MD998709 and MD998742 via a gasket. 3. Install the assembled fuel pressure measurement tools between the fuel rail and the high-pressure fuel hose. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 4. Connect scan tool MB991502 to the data link connector. 5. Use the Actuator test 07 to drive the fuel pump. Check that there is no fuel leaking from any section when the fuel pump is operating. 6. Stop the fuel pump. 7. Start the engine and run at idle. 8. Measure fuel pressure while the engine is running at idle. Standard value: Approximately 270 kPa (38 psi) at curb idle 9. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed with your finger. Standard value: 330 - 350 kPa (47 - 50 psi) at curb idle 10. Check to see that fuel pressure at idle does not drop even after the engine has been revved several times. 11. Revving the engine repeatedly, hold the fuel return hose lightly with your fingers to feel that fuel pressure is present in the return hose. NOTE:If the fuel flow rate is low, there will be no fuel pressure in the return hose. 12. If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1592 13. Stop the engine and observe fuel pressure gauge reading. It is normal if the reading does not drop within two minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Start, then stop the engine. 1. Squeeze the fuel return line closed to confirm leak-down occurs from defective fuel pressure regulator. 2. Squeeze the fuel supply line closed to confirm leak-down occurs from defective fuel pump check valve. 3. If pressure continues to drop with both fuel lines squeezed closed, injector(s) are leaking. 14. Release residual pressure from the fuel pipe line. WARNING Cover the hose connection with shop towels to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. 15. Remove the fuel pressure gauge, and special tools MD998709 and MD998742 from the fuel rail. 16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. 17. Fit the high-pressure fuel hose into the fuel rail and tighten the bolts to specified torque. Tightening torque: 4.9 ± 1.0 (44 ± 8 in. lbs.) 18. Check for fuel leaks. 1. Use scan tool MB991502 to operate the fuel pump. 2. Check the fuel tine for leaks, and repair as needed. 19. Disconnect scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection IDLE MIXTURE CHECK Required Special Tool: MB991502: Scan Tool (MUT-II) 1. Before inspection, set vehicles in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector: 3. Check that the basic ignition timing is within the standard value. Standard value: 5 ± 3 °BTDC 4. Start the engine and increase the engine speed to 2,500 rpm for 2 minutes. 5 Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value: CO contents: 0.5 % or less HC contents: 100 ppm or less 7. If the CO and HC contents do not remain inside the standard value; check the following items: NOTE: Replace the catalytic converter when the CO and HC contents do not remain inside the standard value, even though the result of the inspection is normal for all items. ^ Diagnosis output ^ Closed-loop control (When the closed-loop control is carried out normally, the output signal of the heated oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) ^ Fuel pressures ^ Injector ^ Ignition coil, spark plug cable, spark plug ^ EGR system and EGR valve leak ^ Evaporative emission control system ^ Compression pressure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Basic idle speed .................................................................................................................................. .............................................................. 700 ± 50 rpm Curd idle speed .............................................. ................................................................................................................................................. 700 ± 100 rpm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1599 Idle Speed: Testing and Inspection CURB IDLE SPEED CHECK Required Special Tool: ^ MB991502: Scan Tool (MUT-II) 1. Before inspection and adjustment set vehicles in the following condition. ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB99150 2. 2. Connect scan tool MB991502 to the data link connector. 3. Check the basic ignition timing. Standard value: 5 ± 3 °BTDC 4. Start the engine. 5 Run the engine at idle for 2 minutes. 6. Check the idle speed. Select item number 22 and take a reading of the idle speed. Curb idle speed: 700 ± 100 rpm NOTE: The idle speed is controlled automatically by the idle air control system. 7. If the idle speed is outside the standard value, refer to Multiport Fuel Injection (MFI) Diagnosis Symptom Chart. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1600 Idle Speed: Adjustments BASIC IDLE SPEED ADJUSTMENT Required Special Tool: - MB991502: Scan Tool (MUT-II) NOTE: The standard idle speed has been adjusted with the speed adjusting screw (SAS), by the manufacturer, and there should be no need for readjustment. NOTE: If the adjustment has been changed by mistake, the idle speed may become too high Qr the idle speed may drop too low when loads A/C, defogger, etc. are placed on the engine. If this occurs, adjust by the following procedure. NOTE: The adjustment; if made, should be made after first confirming that the spark plugs, the injectors, the idle air control motor, compression, etc., are all normal. 1. The vehicle should be prepared as follows before the inspection and adjustment. - Engine coolant temperature: 80 - 95 °C (176 - 203 °F) - Lights, electric cooling fan and accessories: OFF - Transaxie: Neutral (A/T for "P" range) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting Qr disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector (16-pin). 3. Start the engine and run at idle. 4. Select the item number 30 of the scan tool Actuator test. NOTE: Use the scan tool to hold the IAC motor at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 700 ± 50 rpm NOTE: The engine speed may be 20 to 100 rpm lower than indicated above for a new vehicle [driven approximately 500 km (300 mile) or less, but no adjustment is necessary. If the engine stalls or the engine speed is low even though the vehicle has been driyen approximately 500 km (300 mile) or more, it is probable that deposits are adhered to the throttle valve, so clean it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1601 6. If not withih the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment. 7. Press the recan tool clear key, and release the IAC motor Actuator test mode. 8. Turn the ignition switch to the "LOCK" (OFF) position. NOTE: Unless the IAC motor is released, the Actuator Test Mode will continue for 27 minutes. 9. Disconnect scan tool MB991502. 10. Start the engine again and let it idle for about 10 minutes. Check that the idling condition is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications Air Cleaner Housing: Specifications Air cleaner bolt ..................................................................................................................................... ................................... 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications > Page 1605 Air Cleaner Housing: Diagrams AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications > Page 1606 Air Cleaner Housing: Service and Repair AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1611 Fuel Pressure Release: Service and Repair FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the instrument panel side cover (driver's side). 2. Disconnect the fuel pump relay (2). 3. Start the engine and let it run until it stops naturally. Turn the ignition switch to the "LOCK" (OFF) position. 4. Connect the fuel pump relay (2). 5. Install the instrument panel side cover (driver's side). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION - 2.4L ENGINE The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft with hydraulic lifters and four valve per cylinder design. The engine is free-wheeling; meaning it has provisions for piston-to-valve clearance. However valve-to-valve interference can occur, if camshafts are rotated independently. cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1616 Firing Order: Mechanical Specifications Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Measure the resistance of the all spark plug leads. 1. Check the cap and coating for cracks. 2. Measure the resistance. Limit: 19 kilo ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................ 0.039 - 0.043 in. (1.0 - 1.1 mm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1631 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................... 18 +/- 4 ft-lb (25 +/- 4 Nm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1632 Spark Plug: Testing and Inspection SPARK PLUG CHECK AND CLEANING <2.4L ENGINE> 1. Check that the plug is not burned, that the insulator plug is not damaged, and that the seizure state is good. 2. If cleaning is required due to carbon deposits, etc., clean using a plug cleaner or wire brush, etc. 3. Check the plug gap using a plug gap gauge, and adjust if not within the standard value. Standard value: 1.0 - 1.1mm (0.039 - 0.043 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressure ........................................................................................................................ ........................................................... (250 - 400 rpm) Standard Value .................................................................................................................................... ................................................ 1,275 kPa (185 psi) Limit (Minimum) ................................................................................................................................... .......................................... 959 kPa (139 psi) Compression pressure difference of all cylinder Limit ..................................................................................................................................................... ............................................... 98 kPa (14 psi) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1636 Compression Check: Testing and Inspection COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights, and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crankshaft position sensor connector. NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel injection. WARNING: Keep your distance from the spark plug hole when cranking. Oil, fuel, etc., may spray out from the spark plug hole and may cause serious injury. 5 Cover the spark plug hole with a shop towel etc., during cranking. After the engine has been cranked, check for foreign material adhering to the shop towel. 6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 - 400 rpm): 1,275 kPa (185 psi) Minimum limit (at engine speed of 250 - 400 rpm): 959 kPa (139 psi) 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: 98 kPa (14 psi) 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 to 8. 1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/ or cylinder inner surface. 2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crankshaft position sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the scan tool to erase the diagnostic trouble codes. NOTE: This will erase the diagnostic trouble code resulting from the crankshaft position sensor connector being disconnected. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water pump pulley attaching bolt ............................................................................................................................................ 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Coolant ................................................................................................................................................ .............................................. 7.0 Liters ( 7.4 qts ) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1646 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 1647 Coolant: Testing and Inspection ENGINE COOLANT LEAK CHECK WARNING: When pressure testing the cooling system, slowly release cooling system pressure to avoid gaffing burned by hot coolant. CAUTION: ^ Be sure to completely clean away any moisture from the places checked. ^ When the tester is taken out, be careful not to spill any coolant from it. ^ Be careful when installing and removing the tester and when testing not to deform the filler neck of the radiator. 1. Check that the coolant level is up to the filler neck. Install a radiator cap tester and apply 160 kPa (23 psi) pressure, and then check for leakage from the radiator hose or connections. 2. If there is leakage, repair or replace the appropriate part. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water hose and water pipe Thermostat case bolt ........................................................................................................................... ..................................... 23 ± 4 Nm (17 ± 3 ft. lbs.) Water inlet pipe assembly bolt ............................................................................................................................................ 13 ± 2 Nm (109 ± 21 in. lbs.) Water outlet fitting bolt ....................................................................................................................................................... 13 ± 2 Nm (109 ± 21 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications > Page 1651 Coolant Line/Hose: Diagrams WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION <2.4L ENGINE> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications > Page 1652 Coolant Line/Hose: Service and Repair WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION <2.4L ENGINE> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications > Page 1653 <3.0L ENGINE> REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications > Page 1654 >>A<< O-RING INSTALLATION CAUTION Do not allow engine oil or other grease to adhere to the O ring. Install the O-ring to the water pipe, and coat the outer portion of the O-ring with water or engine coolant >>B<< WATER OUTLET FITTING <2.4L Engine>/ THERMOSTAT CASE ASSEMBLY <2.4L Engines INSTALLATION Apply a continuous bead of MITSUBISHI GENUINE Sealant Part number MD970389 or equivalent to the thermostat housing mating surface. >>C<< RADIATOR UPPER/LOWER HOSE CONNECTION 1. Insert each hose as far as the projection of the water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose. INSPECTION Water Pipe and Hose Check Check the water pipe and hose for cracks, damage and clogs. Replace them if necessary. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 1659 Radiator Cooling Fan Control Module: Testing and Inspection FAN CONTROLLER CHECK 1. Remove condenser fan motor connector. 2. Start the engine and run it at idle. 3. Turn the A/C switch to ON and maintain the coolant temperature at 80 °C (176 °F) or less. 4. When measuring the voltage between the fan control module-side connector terminals, check that the value changes repeatedly as indicated by (1) - (3) below. (1) 0 Volts (2) 8.2 ± 2.6 Volts (3) Battery positive voltage ± 2.6 Volts 5 If the voltage does not repeatedly change as indicated, replace the radiator fan motor and the fan control module assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids Radiator Cooling Fan Motor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1664 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1665 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1666 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1667 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1668 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1669 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1670 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1671 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1672 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1673 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1674 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1675 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 1676 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications Engine Coolant Temperature (ECT) Sensor: Electrical Specifications ITEM .................................................................................................................................................... ............................................ STANDARD VALUE Engine coolant temperature sensor resistance kOhm -20 °C (-4 °F) ............................................................................................................................ .................................................................................. 14 - 17 0 °C (32 °F) .......................................... .............................................................................................................................................................. ..... 5.1 - 6.5 20 °C (86 °F) ................................................................................................................... ......................................................................................... 2.1 - 2.7 40 °C (104 °F) ............................. .............................................................................................................................................................. ............... 0.9 - 1.3 60 °C (140 °F) ....................................................................................................... ............................................................................................... 0.48 - 0.68 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications > Page 1685 Sealants And Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1686 Engine Coolant Temperature (ECT) Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1687 Engine Coolant Temperature (ECT) Sensor: Testing and Inspection ENGINE COOLANT TEMPERATURE SENSOR CHECK CAUTION: Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Drain engine coolant, then remove the engine coolant temperature sensor. 2. With the temperature sensing portion of engine coolant temperature sensor immersed in hot water, check the resistance. Standard value: 14 - 17 kOhm @ -20 °C (-4 °F) 5.1 - 6.5 kOhm @ 0 °C (32 °F) 2.1 - 2.7 kOhm @ 20 °C (68 °F) 0.9 - 1.3 kOhm @ 40 °C (104 °F) 0.48 - 0.68 kOhm @ 60 °C (140 °F) 0.26 - 0.36 kOhm @ 80 °C (176 °F) 3. If resistance deviates from the standard value greatly, replace the sensor. 4. Apply 3M AAD part number 8731 or equivalent to threaded portion. 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 ± 10 Nm (22 ± ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1688 Engine Coolant Temperature (ECT) Sensor: Service and Repair SEALANTS AND ADHESIVES ITEM .................................................................................................. .......................................................................................... SPECIFIED SEALANT Engine coolant temperature sensor threaded portion ....................................................................................................................................... MOPAR® Part No. 4318031or equivalent Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection 1. Drain the engine coolant. (Refer to Maintenance Service- Engine Coolant.) 2. Remove the engine coolant temperature gauge unit. 3. Immerse the unit in water of 70 °C (158 °F) to measure the resistance. Standard value: 104 ± 13.5 ohms Reference Value 4. If within the standard value, the sensor is OK. Reinstall it, then check the engine coolant temperature gauge. If not within the standard value, replace it. 5. After checking, apply the MOPAR(R) Part No.4318034 or equivalent around the threads of the engine coolant temperature gauge unit. 6. Add engine coolant. (Refer to Maintenance Service Engine Coolant.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications Radiator: Specifications Radiator Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1698 Radiator: Diagrams RADIATOR REMOVAL AND INSTALLATION <2.4L ENGINE> <3.0L ENGINE> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1699 Radiator: Service and Repair RADIATOR REMOVAL AND INSTALLATION <2.4L ENGINE> <3.0L ENGINE> REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 1700 After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications High-pressure valve opening pressure of radiator cap Standard Value .................................................................................................................................... ...................................... 93 - 123 kPa (14 - 18 psi) Limit ..................................................................................................................................................... ............................................... 83 kPa (12 psi) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 1704 Radiator Cap: Testing and Inspection RADIATOR CAP PRESSURE CHECK NOTE: Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an improper indication. 1. Use a cap adapter to attach the cap to the tester. 2. Increase the pressure until the indicator of the gauge stops moving. Minimum limit: 83 kPa (12 psi) Standard value: 93 - 123 kPa (14 - 18 psi) 3. Replace the radiator cap if the reading does not remain at or above the limit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 1709 Radiator Cooling Fan Control Module: Testing and Inspection FAN CONTROLLER CHECK 1. Remove condenser fan motor connector. 2. Start the engine and run it at idle. 3. Turn the A/C switch to ON and maintain the coolant temperature at 80 °C (176 °F) or less. 4. When measuring the voltage between the fan control module-side connector terminals, check that the value changes repeatedly as indicated by (1) - (3) below. (1) 0 Volts (2) 8.2 ± 2.6 Volts (3) Battery positive voltage ± 2.6 Volts 5 If the voltage does not repeatedly change as indicated, replace the radiator fan motor and the fan control module assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications Engine Coolant Temperature (ECT) Sensor: Electrical Specifications ITEM .................................................................................................................................................... ............................................ STANDARD VALUE Engine coolant temperature sensor resistance kOhm -20 °C (-4 °F) ............................................................................................................................ .................................................................................. 14 - 17 0 °C (32 °F) .......................................... .............................................................................................................................................................. ..... 5.1 - 6.5 20 °C (86 °F) ................................................................................................................... ......................................................................................... 2.1 - 2.7 40 °C (104 °F) ............................. .............................................................................................................................................................. ............... 0.9 - 1.3 60 °C (140 °F) ....................................................................................................... ............................................................................................... 0.48 - 0.68 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications > Page 1719 Sealants And Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1720 Engine Coolant Temperature (ECT) Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1721 Engine Coolant Temperature (ECT) Sensor: Testing and Inspection ENGINE COOLANT TEMPERATURE SENSOR CHECK CAUTION: Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Drain engine coolant, then remove the engine coolant temperature sensor. 2. With the temperature sensing portion of engine coolant temperature sensor immersed in hot water, check the resistance. Standard value: 14 - 17 kOhm @ -20 °C (-4 °F) 5.1 - 6.5 kOhm @ 0 °C (32 °F) 2.1 - 2.7 kOhm @ 20 °C (68 °F) 0.9 - 1.3 kOhm @ 40 °C (104 °F) 0.48 - 0.68 kOhm @ 60 °C (140 °F) 0.26 - 0.36 kOhm @ 80 °C (176 °F) 3. If resistance deviates from the standard value greatly, replace the sensor. 4. Apply 3M AAD part number 8731 or equivalent to threaded portion. 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 ± 10 Nm (22 ± ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1722 Engine Coolant Temperature (ECT) Sensor: Service and Repair SEALANTS AND ADHESIVES ITEM .................................................................................................. .......................................................................................... SPECIFIED SEALANT Engine coolant temperature sensor threaded portion ....................................................................................................................................... MOPAR® Part No. 4318031or equivalent Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection 1. Drain the engine coolant. (Refer to Maintenance Service- Engine Coolant.) 2. Remove the engine coolant temperature gauge unit. 3. Immerse the unit in water of 70 °C (158 °F) to measure the resistance. Standard value: 104 ± 13.5 ohms Reference Value 4. If within the standard value, the sensor is OK. Reinstall it, then check the engine coolant temperature gauge. If not within the standard value, replace it. 5. After checking, apply the MOPAR(R) Part No.4318034 or equivalent around the threads of the engine coolant temperature gauge unit. 6. Add engine coolant. (Refer to Maintenance Service Engine Coolant.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications Thermostat: Mechanical Specifications Thermostat Water inlet fitting bolt ......................................................................................................................................................... 13 ± 2 Nm (109 ± 21 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications > Page 1730 Thermostat: Pressure, Vacuum and Temperature Specifications Thermostat Valve opening temperature of thermostat ................................................................................................................................... 88 ± 1.5 °C (190 ± 3 °F) Full-opening temperature of thermostat .................................................................................................................................................... 100 °C (212 °F) Valve lift <2.4L Engine> .......................................................................................................................................................... 8.5 mm (0.33 in.) or more Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1731 Thermostat: Diagrams THERMOSTAT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1732 Thermostat: Service and Repair THERMOSTAT REMOVAL AND INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1733 1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature. Standard value: 88 ± 1.5 °C (190 ± 3 °F) 2. Check that the amount of valve lift is at the standard value when the water is at the full-opening temperature. NOTE: Measure the valve height when the thermostat is fully closed, and use this measurement to calculate the valve height when the thermostat is fully open. Standard value: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water pump pulley attaching bolt ............................................................................................................................................ 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Diagrams Catalytic Converter: Diagrams EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <2.4L> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Diagrams > Page 1742 Catalytic Converter: Description and Operation The three-way catalytic converter, together with the closed loop air-fuel ratio control based on the oxygen sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC) and reduces nitrogen oxides (NOx). When the mixture is controlied at stoichiometric air-fuel ratio, the three-way catalytic converter provides the highest purIfication against the three constituents, namely, CO, HC and NOx. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Diagrams > Page 1743 Catalytic Converter: Service and Repair REMOVAL AND INSTALLATION Removal And Installation Required Special - MD998770: Oxygen Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Diagrams > Page 1744 Use special tool MD998770 to remove the oxygen sensor. INSTALLATION SERVICE POINT >>A<< RIGHT BANK HEATED OXYGEN SENSOR (FRONT)/RIGHT BANK HEATED OXYGEN SENSOR (REAR)/LEFT BANK HEATED OXYGEN SENSOR (REAR)/HEATED OXYGEN SENSOR (REAR) INSTALLATION Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold bracket attaching bolt ...................................................................................................................................... 35 ± 6 Nm (26 ± 4 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1748 Exhaust Manifold: Diagrams EXHAUST MANIFOLD <2.4L> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1749 Exhaust Manifold: Service and Repair EXHAUST MANIFOLD <2.4L> REMOVAL AND INSTALLATION Required Special Tool: ^ MD998770: Oxygen sensor wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1750 Use special tool MD998770 to installation the oxygen sensor. INSPECTION Check the following points; replace the part if a problem is found. Exhaust Manifold Check 1. Check for damage or cracking of any part. 2. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm (0.006 in.) or less Limit: 0.20 mm (0.008 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Front exhaust pipe nut ......................................................................................................................... ....................................... 49 ± 10 Nm (37 ± 7 ft. lbs.) Center exhaust pipe bolt .................................. ............................................................................................................................. 35 ± 4 Nm (26 ± 3 ft. lbs.) Front exhaust pipe nut ............................................................................................................. ................................................... 49 ± 10 Nm (37 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1754 Exhaust Pipe: Diagrams EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <2.4L> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1755 Exhaust Pipe: Service and Repair EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <2.4L> REMOVAL AND INSTALLATION Required Special Tool: ^ MD998770: Oxygen sensor wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 1756 Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Engine hanger nut ............................................................................................................................... .......................................... 29 ± 3 Nm (22 ± 2 ft. lbs.) Hanger bolt ..................................................... ......................................................................................................................... 12 ± 2 Nm (107 ± 17 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat protector bolt ............................................................................................................................... .................................... 14 ± 1 Nm (120 ± 13 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Diagrams Muffler: Diagrams EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <2.4L> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Diagrams > Page 1766 Muffler: Service and Repair EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <2.4L> REMOVAL AND INSTALLATION Required Special Tool: ^ MD998770: Oxygen sensor wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Diagrams > Page 1767 Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1775 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1776 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 1777 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding Engine Control Module: Locations Grounding Grounding Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding > Page 1780 Engine Control Module: Locations ECM/PCM Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Terminal Voltage Check Chart - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 1783 Terminal Voltage Check Chart - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 1784 Terminal Voltage Check Chart - Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 1785 Terminal Voltage Check Chart - Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 1786 Terminal Voltage Check Chart - Part 5 TERMINAL VOLTAGE CHECK CHART Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1790 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1795 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay Continuity Check FUEL PUMP RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1799 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Ignition Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1815 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1816 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1817 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1818 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1819 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1820 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1821 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1822 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1823 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1824 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1825 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check Ignition Control Module: Testing and Inspection Analyser Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method Standard Wave Pattern 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 1828 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 1829 Ignition Control Module: Testing and Inspection Oscilloscope Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 1830 Connect the oscilloscope probe to ECM terminal No.10 (for number 1 number 4), terminal No.23 (for number 2 - number 3) respectively. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1836 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1837 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1841 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1842 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1843 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1844 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications Engine Coolant Temperature (ECT) Sensor: Electrical Specifications ITEM .................................................................................................................................................... ............................................ STANDARD VALUE Engine coolant temperature sensor resistance kOhm -20 °C (-4 °F) ............................................................................................................................ .................................................................................. 14 - 17 0 °C (32 °F) .......................................... .............................................................................................................................................................. ..... 5.1 - 6.5 20 °C (86 °F) ................................................................................................................... ......................................................................................... 2.1 - 2.7 40 °C (104 °F) ............................. .............................................................................................................................................................. ............... 0.9 - 1.3 60 °C (140 °F) ....................................................................................................... ............................................................................................... 0.48 - 0.68 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications > Page 1849 Sealants And Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1850 Engine Coolant Temperature (ECT) Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1851 Engine Coolant Temperature (ECT) Sensor: Testing and Inspection ENGINE COOLANT TEMPERATURE SENSOR CHECK CAUTION: Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Drain engine coolant, then remove the engine coolant temperature sensor. 2. With the temperature sensing portion of engine coolant temperature sensor immersed in hot water, check the resistance. Standard value: 14 - 17 kOhm @ -20 °C (-4 °F) 5.1 - 6.5 kOhm @ 0 °C (32 °F) 2.1 - 2.7 kOhm @ 20 °C (68 °F) 0.9 - 1.3 kOhm @ 40 °C (104 °F) 0.48 - 0.68 kOhm @ 60 °C (140 °F) 0.26 - 0.36 kOhm @ 80 °C (176 °F) 3. If resistance deviates from the standard value greatly, replace the sensor. 4. Apply 3M AAD part number 8731 or equivalent to threaded portion. 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 ± 10 Nm (22 ± ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 1852 Engine Coolant Temperature (ECT) Sensor: Service and Repair SEALANTS AND ADHESIVES ITEM .................................................................................................. .......................................................................................... SPECIFIED SEALANT Engine coolant temperature sensor threaded portion ....................................................................................................................................... MOPAR® Part No. 4318031or equivalent Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1875 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1876 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1877 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1878 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 1879 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 1880 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 1881 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 1882 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Engine Speed Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1889 Fuel Tank Pressure Sensor: Testing and Inspection FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK 1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991348 between the terminals of the disconnected connector. 2. Turn the ignition switch to "ON" and measure the output voltage between terminals 2 and 3. Standard value: 2.0 - 3.0 V Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1890 Special Tools Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake air temperature sensor resistance kOhm .................................................................................................................................. STANDARD VALUE -20 °C (-4 °F) ....................................................................................................................................... ....................................................................... 13 - 17 0 °C (32 °F) ..................................................... ......................................................................................................................................................... 5.3 - 6.7 20 °C (86° F) ......................................................................................................................... ................................................................................... 2.3 - 3.0 40 °C (104 °F) ................................... .............................................................................................................................................................. ......... 1.0 - 1.5 60 °C (140 °F) ............................................................................................................. ......................................................................................... 0.56 - 0.76 80 °C (176 °F) ......................... .............................................................................................................................................................. ............... 0.30 - 0.42 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1894 Intake Air Temperature (IAT) Sensor: Locations The Intake Air Temperature sensor is incorporated into the Mass Airflow Sensor and is not serviceable seperately. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1895 Intake Air Temperature (IAT) Sensor: Testing and Inspection INTAKE AIR TEMPERATURE SENSOR CHECK 1. Disconnect the volume air flow sensor connectors. 2. Measure resistance between terminals 5 and 6. Standard value: 13 - 17 kohm @ -20 °C (-4 °F) 5.3 - 6.7 kohm @ 0 °C (32 °F) 2.3 - 3.0 kohm @ 20 °C (68 °F) 1.0 - 1.5 kohm @ 40 °C (104 °F) 0.56 - 0.76 kohm @ 60 °C (140 °F) 0.30 - 0.42 kohm @ 80 °C (176 °F) 3. If not within specifications, replace the volume air flow sensor. 4. Measure resistance while heating the sensor using a hair dryer. Normal condition: TEMPERATURE RESISTANCE (kohm) Higher Smaller 5. If resistance does not decrease as heat increases, replace the volume air flow sensor assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1907 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1908 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1922 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1923 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated oxygen sensor output voltage V .............................................................................................. ...................................................................... 0.6 - 1.0 Heated oxygen sensor heater resistance Q ... .............................................................................................................................................................. .................................................... 4.5 - 8.0 .......................................................................................... .............................................................................................................................. 11 - 18 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1930 Oxygen Sensor: Locations View G Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1931 View b Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1932 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1933 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR CHECK Required Special Tools: - MB991658: Test Harness Set - MD998464: Test Harness 1. Using the scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MD998464 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [4.5 - 8.0 Ohm at 20 °C (68 °F) between terminal No.1 (red clip of special tool) and terminal No.3 (blue clip of special tool) on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.1 (red clip) of the heated oxygen sensor connector to the positive battery terminal and terminal No.3 (blue clip) to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.2 (black clip) and terminal No.4 (white clip). 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1934 NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. 1. Using scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MB991658 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [11 - 18 Ohm at 20 °C (68 °F) between terminal No.5 and terminal No.6 on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.5 of the heated oxygen sensor connector to the positive battery terminal and terminal No.6 to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.3 and terminal No.4. 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1935 Oxygen Sensor: Service and Repair REMOVAL AND INSTALLATION Removal And Installation Required Special - MD998770: Oxygen Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1936 Use special tool MD998770 to remove the oxygen sensor. INSTALLATION SERVICE POINT >>A<< RIGHT BANK HEATED OXYGEN SENSOR (FRONT)/RIGHT BANK HEATED OXYGEN SENSOR (REAR)/LEFT BANK HEATED OXYGEN SENSOR (REAR)/HEATED OXYGEN SENSOR (REAR) INSTALLATION Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1943 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1944 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1945 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1946 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1947 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations View D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1951 Vehicle Speed Sensor: Testing and Inspection VEHICLE SPEED SENSOR CHECK 1. Remove the vehicle speed sensor and connect a 3-10 kilo ohm resistor as shown in the illustration. 2. Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2 - 3. (1 turn = 4 pulses) 3. If within the standard value, the vehicle speed sensor is OK. If not within the standard value, replace the vehicle speed sensor. Standard value: Voltage alternates between 0 volt and 5 volts four times per turn. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1952 Vehicle Speed Sensor: Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1953 Disassembly And Assembly Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1958 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1959 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil pressure switch .............................................................................................................................. ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1966 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1967 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1968 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1969 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1970 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1975 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1976 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1977 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1978 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1987 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1988 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1989 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1990 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1991 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1992 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1993 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1994 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1995 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1996 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1997 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1998 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1999 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2000 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2001 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2002 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2003 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2004 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2005 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2006 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2007 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2008 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2026 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2027 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2028 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2029 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2030 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2031 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2032 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2033 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2034 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2035 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2036 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure kPa (psi) Vacuum hose disconnected ................................................................................................................................................... 330 350 (47 - 50) at curb idle Vacuum hose connected ............................................................................................................................................... Approximately 270 (38) at curb idle Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2041 Fuel Pressure: Testing and Inspection FUEL PRESSURE TEST Required Special Tools: - MB9915Q2: Scan Tool (MUT-II) - MB991637: Fuel Pressure Gauge Set - MD998709: Adaptor Hose - MD998742: Hose Adaptor 1. Release residual pressure from the fuel line to prevent fuel spray. WARNING To prevent a fire, cover the hose connection with shop towels to prevent splashing of fuel that could be caused by Some residual pressure in the fuel pipe line. 2. Disconnect the high-pressure fuel hose at the fuel rail side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2042 3. Assemble the fuel pressure measurement tools as follows. 1. Rempve the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Place a suitable O-ring or gasket on assembled special tools MD998709 and MD998742 and install the fuel pressure gauge. 3. Install the assembled fuel pressure measurement tools between the fuel rail and high-pressure fuel hose. 1. Remove the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Install special tool MB991637 (fuel pressure gauge set) to assembled special tools MD998709 and MD998742 via a gasket. 3. Install the assembled fuel pressure measurement tools between the fuel rail and the high-pressure fuel hose. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 4. Connect scan tool MB991502 to the data link connector. 5. Use the Actuator test 07 to drive the fuel pump. Check that there is no fuel leaking from any section when the fuel pump is operating. 6. Stop the fuel pump. 7. Start the engine and run at idle. 8. Measure fuel pressure while the engine is running at idle. Standard value: Approximately 270 kPa (38 psi) at curb idle 9. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed with your finger. Standard value: 330 - 350 kPa (47 - 50 psi) at curb idle 10. Check to see that fuel pressure at idle does not drop even after the engine has been revved several times. 11. Revving the engine repeatedly, hold the fuel return hose lightly with your fingers to feel that fuel pressure is present in the return hose. NOTE:If the fuel flow rate is low, there will be no fuel pressure in the return hose. 12. If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2043 13. Stop the engine and observe fuel pressure gauge reading. It is normal if the reading does not drop within two minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Start, then stop the engine. 1. Squeeze the fuel return line closed to confirm leak-down occurs from defective fuel pressure regulator. 2. Squeeze the fuel supply line closed to confirm leak-down occurs from defective fuel pump check valve. 3. If pressure continues to drop with both fuel lines squeezed closed, injector(s) are leaking. 14. Release residual pressure from the fuel pipe line. WARNING Cover the hose connection with shop towels to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. 15. Remove the fuel pressure gauge, and special tools MD998709 and MD998742 from the fuel rail. 16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. 17. Fit the high-pressure fuel hose into the fuel rail and tighten the bolts to specified torque. Tightening torque: 4.9 ± 1.0 (44 ± 8 in. lbs.) 18. Check for fuel leaks. 1. Use scan tool MB991502 to operate the fuel pump. 2. Check the fuel tine for leaks, and repair as needed. 19. Disconnect scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection IDLE MIXTURE CHECK Required Special Tool: MB991502: Scan Tool (MUT-II) 1. Before inspection, set vehicles in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector: 3. Check that the basic ignition timing is within the standard value. Standard value: 5 ± 3 °BTDC 4. Start the engine and increase the engine speed to 2,500 rpm for 2 minutes. 5 Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value: CO contents: 0.5 % or less HC contents: 100 ppm or less 7. If the CO and HC contents do not remain inside the standard value; check the following items: NOTE: Replace the catalytic converter when the CO and HC contents do not remain inside the standard value, even though the result of the inspection is normal for all items. ^ Diagnosis output ^ Closed-loop control (When the closed-loop control is carried out normally, the output signal of the heated oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) ^ Fuel pressures ^ Injector ^ Ignition coil, spark plug cable, spark plug ^ EGR system and EGR valve leak ^ Evaporative emission control system ^ Compression pressure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Basic idle speed .................................................................................................................................. .............................................................. 700 ± 50 rpm Curd idle speed .............................................. ................................................................................................................................................. 700 ± 100 rpm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2050 Idle Speed: Testing and Inspection CURB IDLE SPEED CHECK Required Special Tool: ^ MB991502: Scan Tool (MUT-II) 1. Before inspection and adjustment set vehicles in the following condition. ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB99150 2. 2. Connect scan tool MB991502 to the data link connector. 3. Check the basic ignition timing. Standard value: 5 ± 3 °BTDC 4. Start the engine. 5 Run the engine at idle for 2 minutes. 6. Check the idle speed. Select item number 22 and take a reading of the idle speed. Curb idle speed: 700 ± 100 rpm NOTE: The idle speed is controlled automatically by the idle air control system. 7. If the idle speed is outside the standard value, refer to Multiport Fuel Injection (MFI) Diagnosis Symptom Chart. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2051 Idle Speed: Adjustments BASIC IDLE SPEED ADJUSTMENT Required Special Tool: - MB991502: Scan Tool (MUT-II) NOTE: The standard idle speed has been adjusted with the speed adjusting screw (SAS), by the manufacturer, and there should be no need for readjustment. NOTE: If the adjustment has been changed by mistake, the idle speed may become too high Qr the idle speed may drop too low when loads A/C, defogger, etc. are placed on the engine. If this occurs, adjust by the following procedure. NOTE: The adjustment; if made, should be made after first confirming that the spark plugs, the injectors, the idle air control motor, compression, etc., are all normal. 1. The vehicle should be prepared as follows before the inspection and adjustment. - Engine coolant temperature: 80 - 95 °C (176 - 203 °F) - Lights, electric cooling fan and accessories: OFF - Transaxie: Neutral (A/T for "P" range) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting Qr disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector (16-pin). 3. Start the engine and run at idle. 4. Select the item number 30 of the scan tool Actuator test. NOTE: Use the scan tool to hold the IAC motor at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 700 ± 50 rpm NOTE: The engine speed may be 20 to 100 rpm lower than indicated above for a new vehicle [driven approximately 500 km (300 mile) or less, but no adjustment is necessary. If the engine stalls or the engine speed is low even though the vehicle has been driyen approximately 500 km (300 mile) or more, it is probable that deposits are adhered to the throttle valve, so clean it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2052 6. If not withih the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment. 7. Press the recan tool clear key, and release the IAC motor Actuator test mode. 8. Turn the ignition switch to the "LOCK" (OFF) position. NOTE: Unless the IAC motor is released, the Actuator Test Mode will continue for 27 minutes. 9. Disconnect scan tool MB991502. 10. Start the engine again and let it idle for about 10 minutes. Check that the idling condition is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications Air Cleaner Housing: Specifications Air cleaner bolt ..................................................................................................................................... ................................... 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications > Page 2056 Air Cleaner Housing: Diagrams AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Specifications > Page 2057 Air Cleaner Housing: Service and Repair AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2062 Fuel Pressure Release: Service and Repair FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the instrument panel side cover (driver's side). 2. Disconnect the fuel pump relay (2). 3. Start the engine and let it run until it stops naturally. Turn the ignition switch to the "LOCK" (OFF) position. 4. Connect the fuel pump relay (2). 5. Install the instrument panel side cover (driver's side). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION - 2.4L ENGINE The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft with hydraulic lifters and four valve per cylinder design. The engine is free-wheeling; meaning it has provisions for piston-to-valve clearance. However valve-to-valve interference can occur, if camshafts are rotated independently. cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2067 Firing Order: Mechanical Specifications Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Measure the resistance of the all spark plug leads. 1. Check the cap and coating for cracks. 2. Measure the resistance. Limit: 19 kilo ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................ 0.039 - 0.043 in. (1.0 - 1.1 mm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2082 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................... 18 +/- 4 ft-lb (25 +/- 4 Nm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2083 Spark Plug: Testing and Inspection SPARK PLUG CHECK AND CLEANING <2.4L ENGINE> 1. Check that the plug is not burned, that the insulator plug is not damaged, and that the seizure state is good. 2. If cleaning is required due to carbon deposits, etc., clean using a plug cleaner or wire brush, etc. 3. Check the plug gap using a plug gap gauge, and adjust if not within the standard value. Standard value: 1.0 - 1.1mm (0.039 - 0.043 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressure ........................................................................................................................ ........................................................... (250 - 400 rpm) Standard Value .................................................................................................................................... ................................................ 1,275 kPa (185 psi) Limit (Minimum) ................................................................................................................................... .......................................... 959 kPa (139 psi) Compression pressure difference of all cylinder Limit ..................................................................................................................................................... ............................................... 98 kPa (14 psi) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2087 Compression Check: Testing and Inspection COMPRESSION PRESSURE CHECK 1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights, and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crankshaft position sensor connector. NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel injection. WARNING: Keep your distance from the spark plug hole when cranking. Oil, fuel, etc., may spray out from the spark plug hole and may cause serious injury. 5 Cover the spark plug hole with a shop towel etc., during cranking. After the engine has been cranked, check for foreign material adhering to the shop towel. 6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 - 400 rpm): 1,275 kPa (185 psi) Minimum limit (at engine speed of 250 - 400 rpm): 959 kPa (139 psi) 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: 98 kPa (14 psi) 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 6 to 8. 1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/ or cylinder inner surface. 2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crankshaft position sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the scan tool to erase the diagnostic trouble codes. NOTE: This will erase the diagnostic trouble code resulting from the crankshaft position sensor connector being disconnected. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2092 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2093 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake air temperature sensor resistance kOhm .................................................................................................................................. STANDARD VALUE -20 °C (-4 °F) ....................................................................................................................................... ....................................................................... 13 - 17 0 °C (32 °F) ..................................................... ......................................................................................................................................................... 5.3 - 6.7 20 °C (86° F) ......................................................................................................................... ................................................................................... 2.3 - 3.0 40 °C (104 °F) ................................... .............................................................................................................................................................. ......... 1.0 - 1.5 60 °C (140 °F) ............................................................................................................. ......................................................................................... 0.56 - 0.76 80 °C (176 °F) ......................... .............................................................................................................................................................. ............... 0.30 - 0.42 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2097 Intake Air Temperature (IAT) Sensor: Locations The Intake Air Temperature sensor is incorporated into the Mass Airflow Sensor and is not serviceable seperately. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2098 Intake Air Temperature (IAT) Sensor: Testing and Inspection INTAKE AIR TEMPERATURE SENSOR CHECK 1. Disconnect the volume air flow sensor connectors. 2. Measure resistance between terminals 5 and 6. Standard value: 13 - 17 kohm @ -20 °C (-4 °F) 5.3 - 6.7 kohm @ 0 °C (32 °F) 2.3 - 3.0 kohm @ 20 °C (68 °F) 1.0 - 1.5 kohm @ 40 °C (104 °F) 0.56 - 0.76 kohm @ 60 °C (140 °F) 0.30 - 0.42 kohm @ 80 °C (176 °F) 3. If not within specifications, replace the volume air flow sensor. 4. Measure resistance while heating the sensor using a hair dryer. Normal condition: TEMPERATURE RESISTANCE (kohm) Higher Smaller 5. If resistance does not decrease as heat increases, replace the volume air flow sensor assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2102 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2103 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2104 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2105 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications Engine Coolant Temperature (ECT) Sensor: Electrical Specifications ITEM .................................................................................................................................................... ............................................ STANDARD VALUE Engine coolant temperature sensor resistance kOhm -20 °C (-4 °F) ............................................................................................................................ .................................................................................. 14 - 17 0 °C (32 °F) .......................................... .............................................................................................................................................................. ..... 5.1 - 6.5 20 °C (86 °F) ................................................................................................................... ......................................................................................... 2.1 - 2.7 40 °C (104 °F) ............................. .............................................................................................................................................................. ............... 0.9 - 1.3 60 °C (140 °F) ....................................................................................................... ............................................................................................... 0.48 - 0.68 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications > Page 2110 Sealants And Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2111 Engine Coolant Temperature (ECT) Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2112 Engine Coolant Temperature (ECT) Sensor: Testing and Inspection ENGINE COOLANT TEMPERATURE SENSOR CHECK CAUTION: Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Drain engine coolant, then remove the engine coolant temperature sensor. 2. With the temperature sensing portion of engine coolant temperature sensor immersed in hot water, check the resistance. Standard value: 14 - 17 kOhm @ -20 °C (-4 °F) 5.1 - 6.5 kOhm @ 0 °C (32 °F) 2.1 - 2.7 kOhm @ 20 °C (68 °F) 0.9 - 1.3 kOhm @ 40 °C (104 °F) 0.48 - 0.68 kOhm @ 60 °C (140 °F) 0.26 - 0.36 kOhm @ 80 °C (176 °F) 3. If resistance deviates from the standard value greatly, replace the sensor. 4. Apply 3M AAD part number 8731 or equivalent to threaded portion. 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 ± 10 Nm (22 ± ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2113 Engine Coolant Temperature (ECT) Sensor: Service and Repair SEALANTS AND ADHESIVES ITEM .................................................................................................. .......................................................................................... SPECIFIED SEALANT Engine coolant temperature sensor threaded portion ....................................................................................................................................... MOPAR® Part No. 4318031or equivalent Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2120 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2121 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2122 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2123 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2124 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2125 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2126 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2127 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2128 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2129 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2130 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2131 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2132 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2133 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2134 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2135 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2136 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2137 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2138 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2139 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2140 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2141 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2142 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2143 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations Data Link Connector: Component Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations > Page 2148 Inspection Terminal Location Index, Overall View And Views A - B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling Electronic Throttle Actuator: Technical Service Bulletins Safety Systems - Inadvertent Damage/Disabling NUMBER: 08-027-04 GROUP: Electrical DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-017-01, DATED SEPTEMBER 21, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND YEARS. SUBJECT: Safety Systems - Vehicle Modifications/Repair MODELS: 2002 - **2003** (AB) Ram Van/Wagon 2002 - **2004** (AN) Dakota 2002 (BR/BE) Ram Pickup **2004 - 2005 (CS) Pacifica** 2002 - **2003** (DN) Durango **2003 - 2005 (DR/DH) Ram Pickup** **2004 - 2005 (HB) Durange 2002 - **2005** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 - **2005** (KJ) Liberty 2002 - **2004** (LH) Concorde/Intrepid/300M **2005 (LX) 300/Magnum ** **2005 (ND) Dakota** 2002 (PG) PT Cruiser (International Markets) 2002 - **2005** (PL) Neon 2002 - **2003** (PR) Prowler 2002 - **2005** (PT) Chrysler PT Cruiser 2002 - **2005** (RS) Town & Country/Caravan/Voyager 2002 - **2005** (RG) Chrysler Voyager (International Markets) 2002 (SR) Viper 2002 - **2005** (ST) Sebring Coupe/Stratus Coupe 2002 - **2005** (TJ) Wrangler **2002 - 2005 (VA) Sprinter** 2002 - **2004** (WJ) Grand Cherokee **2005 (WK) Grand Cherokee** Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling > Page 2153 2002 - **2004** (WG) Grand Cherokee (International Markets) **2005 (WH) Grand Cherokee (International Markets)** **2003 - 2005 (ZB) Viper** **2004 - 2005 (ZH) Crossfire** DISCUSSION: Current DaimlerChrysler vehicles may contain any or all of the following safety Systems: driver airbags, passenger airbags, side curtain airbags, side seat airbags, seat belt pre-tensioners, anti-lock brakes, electronic throttle control, or traction control. All these systems contain multiple sophisticated sensitive electrical and mechanical components. The location and function of all safety system components must be determined before performing repairs; including accident, mechanical or electrical, or vehicle modifications such as adding an after-market sunroof. WARNING: ANY INADVERTENT SAFETY SYSTEM COMPONENT OR ASSOCIATED WIRING DAMAGE/MODIFICATION OR COMPONENT LOCATION CHANGE MAY DISABLE ANY OF THE SAFETY SYSTEMS. Refer to the appropriate vehicle Service Information to determine location and function of all safety systems before servicing vehicle. All systems should be checked for functionality after the vehicle modifications/repairs are complete. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2158 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2159 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2160 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding Engine Control Module: Locations Grounding Grounding Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding > Page 2163 Engine Control Module: Locations ECM/PCM Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Terminal Voltage Check Chart - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2166 Terminal Voltage Check Chart - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2167 Terminal Voltage Check Chart - Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2168 Terminal Voltage Check Chart - Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2169 Terminal Voltage Check Chart - Part 5 TERMINAL VOLTAGE CHECK CHART Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Engine Speed Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2176 Fuel Tank Pressure Sensor: Testing and Inspection FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK 1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991348 between the terminals of the disconnected connector. 2. Turn the ignition switch to "ON" and measure the output voltage between terminals 2 and 3. Standard value: 2.0 - 3.0 V Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2177 Special Tools Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications Idle Air Control Motor Coil Resistance ................................................................................................................................. 28 - 33 ohms @ 20 °C (68 °F) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2181 Idle Air Control (IAC) Motor: Locations Overall View View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test Idle Air Control (IAC) Motor: Testing and Inspection Oscilloscope Test IDLE AIR CONTROL MOTOR (STEPPER MOTOR) Required Special Tool: - MB991709: Test Harness Set Measurement Method 1. Disconnect the idle air control motor connector, and connect the test harness special tool, MB991709 in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the idle air control motor connector terminal No.1, terminal No.3, terminal No.4 and terminal No.6, respectively. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2184 Wave Pattern Observation Points Check that the standard wave pattern appears when the idle air control motor is operating. PointA: Wave Pattern Observation Points Presence or absence of induced electromotive force from the motor turning. (Refer to abnormal wave pattern.) Point B: Wave Pattern Observation Points Height of coil back electromotive force Examples of Abnormal Wave Patterns Example 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2185 - Cause of problem Malfunction of motor. (Motor is not operating.) - Wave pattern characteristics Induced electromotive force from the motor turning does not appear. Example 2 - Cause of problem Open circuit in the line between the idle air control motor and the ECM or PCM. - Wave pattern characteristics Current is not supplied to the motor coil on the open circuit side. (Voltage does not drop to 0 volt.) Furthermore, the induced electromotive force wave pattern at the normal side is slightly different from the normalwave pattern. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2186 Idle Air Control (IAC) Motor: Testing and Inspection Resistance Test IDLE AIR CONTROL MOTOR (STEPPER MOTOR) CHECK Required Special Tool: - MB991709: Test Harness Set Checking the Operation Sound 1. Check that the engine coolant temperature is 20 °C (68 °F) or below. NOTE: If necessary you can disconnect the engine coolant temperature sensor connector and connect the harness-side of the connector to another engine coolant temperature sensor that is at 20 °C (68 °F) or below. 2. Check that the operation sound of the stepper motor can be heard after the ignition is switched ON (but do not start the engine). 3. If the operation sound cannot be heard, check the stepper motor's activation circuit. If the circuit is normal, it is probable that there is a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2187 2. Measure resistance between terminal No. 2 and either terminal No. 1 or terminal No. 3 of the connector at the idle air control motor side. Standard value: 28 - 33 ohms @ 20 °C (68 °F) 3. If resistance is not within the standard value, replace the IAC motor. 4. Measure the resistance between terminal No. 5 and either terminal No. 6 or terminal No. 4 of the connector at the idle air control motor side. Standard value: 28 - 33 ohms @ 20 °C (68 °F) 5. If resistance is not within the standard value, replace the IAC motor 1. Remove the throttle body. 2. Remove the idle air control motor. 3. Connect special tool MB991709 to the idle air control motor connector. 4. Connect the positive (+) terminal of a power supply (approximately 6 volts) to terminal No. 2 and the terminal No. 5. 5. Connect the negative (-) terminal of the power supply to each clip as described in the following steps. Then check whether or not the stepper motor vibrates slightly as it operates. 1. Connect the negative terminal of the power supply to terminal No. 1 and terminal No. 4. 2. Connect the negative terminal of the power supply to terminal No. 3 and terminal No. 4. 3. Connect the negative terminal of the power supply to terminal No. 3 and terminal No. 6. 4. Connect the negative terminal of the power supply to terminal No. 1 and terminal No. 6. 5. Connect the negative terminal of the power supply to terminal No. 1 and terminal No. 4. 6. Repeat the tests in sequence from (5) to (1) to test opposite movement of the IAC. 6. If vibration is detected during the test, the stepper motor can be considered to be normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation Information Bus: Description and Operation COMMUNICATION METHOD As shown, signal wires used exclusively for transmitting multiplex signal data connect the ETACS-ECU, front-ECU, column switch (incorporating the column-ECU) and sunroof motor assembly (incorporating the sunroof-ECU) and these components communicate with each other. OPERATION TONE ALARM FUNCTION Ignition Key Reminder Tone Alarm Function When the driver's door is opened (driver's door switch ON) without removing the ignition key [ignition switch to "LOCK" (OFF) or "ACC" position], the tone alarm will sound intermittently to remind the driver that the ignition key has not been removed. Light Reminder Tone Alarm Function When the driver's door is opened (driver's door switch ON) with lighting switch (taillight switch or headlight switch) in the ON position and ignition switch in the "LOCK" (OFF) or "ACC" position, the tone alarm will sound continuously to remind the driver that the lights (taillights or headlights) are ON. This function does not work if the taillights or headlights are switched 0ff through the headlight automatic shutdown function. In addition, the ignition key reminder tone alarm function has a priority over this function. Door Ajar Tone Alarm Function If any of the doors are open, with ignition switch "ON" and with vehicle running at the speed of 8 km/h (5 mph) or more, ETACS-ECU makes buzzer sound. Low Washer Fluid Level Tone Alarm If 10 seconds have passed after ignition switch has been turned "ON," and then, washer fluid level switch remains at the position "ON" (alarms for washer fluid level getting low) for two seconds or more, ETACS-ECU makes buzzer sound.Buzzer sounds just once after setting ignition switch to the position "ON." Seat Belt Tone Alarm Function When the ignition switch is turned to "ON" position without fastening the seat belts (seat belt switch OFF), the tone alarm will sound for approximately six seconds to warn the driver to fasten the seat belts. When the seat belts are fastened, the tone alarm will stop sounding. Low Fuel Level Tone Alarm Function If seven seconds have passed after ignition switch has been set to the position "ON," and then, low fuel level signal (low fuel level alarm light) from ECM or PCM, is turned "ON," ETACS-ECU makes buzzer sound.Buzzer sounds just once after setting ignition switch to the position "ON." CENTRAL DOOR LOCKING SYSTEM Central Door Locking System Operation When the driver's inside lock knob is locked or unlocked, the lock relay inside the ETACS-ECU turns on to lock or unlock all doors. With all the doors locked, turning the key in the driver's door unlocks the door. Turning it again makes the door unlock relay close to send a signal for unlocking all doors. When the door lock switch (built into the power window switch) is operated, the lock or unlock relay inside the ETACS-ECU is turned on to lock or unlock all doors. Forgotten Key Prevention Function If the driver's door is open (door switch turned ON), when the key is inserted in the ignition switch (key reminder switch turned OFF), the ETACS-ECU activates the door unlock relay for 0.5 second to prevent the door from being locked. If you try to lock either the driver's or passenger's door when the passenger's door is open (door switch turned ON) and the key is inserted in the ignition switch (key reminder switch turned OFF), the ETACS-ECU prevents the doors from being locked by activating the door unlock relay for Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Page 2191 0.5 second. Rolling Lock Function If any of the doors are unlocked, with ignition switch "ON" and with vehicle running at the speed of 24 km/h (15 mph) or more (and such a condition continues over 2 seconds), lock relay output is turned "ON." Lock relay output is turned "OFF" when all the doors are locked, and thus the operating sound is lowered down.(outputs for 0.1 - 0.5 seconds) NOTE: The rolling lock function can be disabled by the configuration function. Refer to Door On-Vehicle Service. POWER WINDOW RELAY CONTROL Power Window Relay Operation If the ignition switch is turned to "ON" position, the power window relay is energized to activate the power windows. Power Window Timer Function When the ignition switch is turned from the "ON" position to "LOCK" (OFF) or "ACC" position, the power windows can be operated for thirty seconds. If any door is opened for the thirty seconds, the power windows will be immobilized at that point. KEYLESS ENTRY SYSTEM Keyless Entry Answerback Function If the RKE transmitter "LOCK" or "UNLOCK" switch is pressed while the ignition key is removed, the doors can be locked or unlocked. If the doors are closed, the hazard warning lights, the interior lights and the horn will operate due to answerback function. Because of the answerback function, the hazard warning lights flash twice, and the horn sounds once, the interior lights flashes twice when the doors are locked. Meanwhile, when the doors are unlocked, the hazard warning lights flash and the interior lights illuminates for thirty seconds. The hazard and the horn answerback functions can be cancelled by using the transmitter. Trunk Lid Opener Function After "TRUNK" switch of the transmitter is turned "ON" twice within 5 seconds without ignition key in the key hole, ETACS-ECU makes trunk lid opener actuator open the trunk lid. SUNROOF Sunroof Operation All of the slide open/close, tilt up/down, and stop operations can be performed by a single switch. When the roof lid glass is tilted up, the sunshade opens approximately 98 mm (3.9 inches) in combined operation with the roof lid glass for better ventilation. A jam preventing mechanism has been adopted. When a slide-close or tilt-down operation is blocked by an external force, the roof lid glass moves back and stops. The electronic sunroof system cannot be operated manually. The sunroof wrench that was used in previous models is not provided. If the anti-jam mechanism reverses the sunroof five or more times consecutively due to deformation or other problem with the sunroof components, it deactivates and allows the sunroof to make small movements [30 mm (1.2 inches)] until it closes completely. Sunroof Timer Function When the ignition switch is turned from "ON" position to "LOCK" (OFF) or "ACC" position, the sunroof can be operated for thirty seconds. If any door is opened for the thirty seconds, the sunroof will be immobilized at that point. WINDSHIELD WIPERS AND WASHERS Windshield Low-speed (and High-speed) Wiper Operation If the windshield low-speed wiper switch is turned to ON position with the ignition switch at the "ACC" or "ON" position, the column switch sends a low-speed wiper ON and high-speed wiper OFF signals to the front-ECU. This turns the wiper signal on and the wiper speed switching relay off (low-speed), causing the wipers to operate at low-speed. If the windshield high-speed wiper switch is turned to the ON position, the column switch sends a low-speed wiper OFF and high-speed wiper ON signals to the front-ECU. This turns both the wiper signal and the wiper speed switching relay on (high-speed), causing the wipers to operate at high-speed. Windshield Intermittent Wiper Operation The ETACS-ECU calculates the wiper operation interval according to the voltage signal sent from the column switch and vehicle speed. Then the ETACS- ECU sends a signal to the front-ECU. The front-ECU determines the wiper operation interval and turns on the wiper relay signal relay. This causes the wiper auto stop relay to turn on. Then the wiper auto stop relay will turn off after the wipers reach the park position. This causes the wiper signal relay and then the wipers to turn off. If the wiper signal relay remains off for the wiper operation interval, the relay turns on again, Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Page 2192 causing the wipers to operate in intermittent mode. Windshield Mist Wiper Operation If the windshield mist wiper switch is turned to the ON position with the ignition switch at the "ACC" or "ON" position, the mist wiper high-speed operation signal is sent to the front-ECU. This signal turns on the wiper speed switching relay, causing the wipers to work at high-speed while the mist switch is on. While the windshield mist wiper switch remains turned on when the intermittent mode is still working, the wipers work as the mist wiper. However, the wipers return to the intermittent mode again when the switch is changed back to "INT." Windshield Washer Operation If the windshield washer switch is turned to ON position with the ignition switch at "ACC" or "ON" position, the windshield washer ON signal is sent to the front-ECU, causing the windshield wiper signal to turn on after 0.15 seconds. After the windshield washer switch signal turns off, the windshield wiper signal turns off in three seconds. If the windshield wiper switch is turned to the ON position while the windshield wiper is at intermittent mode, the windshield washer works for that period when the windshield washer switch remains on. Then the wipers return to the intermittent mode. Low Washer Fluid Level Warning Light If Ignition switch and washer fluid level switch remains "ON" (the latter alarms for washer fluid level getting low) for 2 seconds or more, ETACS-ECU illuminates low washer fluid level warning light. Even if washer fluid level switch is set to the position "OFF", ETACS-ECU illuminate low washer fluid level warning light for the following 2 seconds. SEAT BELT WARNING LIGHT If the driver turns the ignition switch to the "ON" position without wearing the seat belt, the seat belt warning light illuminates to alert the driver to wear the seat belt. IGNITION KEY HOLE ILLUMINATION LIGHT When the ignition switch is turned to the "LOCK" (OFF) or "ACC" position with the driver's door opened, the ignition key hole illumination light is illuminated. If the door is closed in that state, the light goes out after 30 seconds or it illuminates for 30 seconds after the ignition key is removed. In either case the light does out when the ignition switch is turned to the "ON" position. DOOR AJAR WARNING LIGHT If any of the doors or the trunk lid are open, ETACS-ECU illuminates door ajar warning light. HEADLIGHT Headlight Automatic Shutdown Function If ignition switch is set to the position "OFF" with lighting switch (taillight switch and headlight switch) "ON," illumination is automatically turned off after 10 minutes to prevent battery's running out.If lighting switch is set to the position "OFF" 45 seconds or more after ignition switch is set to the position "OFF," illumination is immediately turned off.Next time the lighting switch is set to the position "ON," illumination won't be automatically turned off. If headlight switch and taillight switch are set to the position "OFF" within 45 seconds after headlight switch is set to the position "ON" and ignition switch to the position "OFF," ETACS-ECU illuminates only the headlight for the following 60 seconds. If the lighting switch is, again, set to the position "ON" and then to the position "OFF" within the 60 seconds, illumination is immediately turned off. Headlight Dimmer Switch Automatic Resetting Function This function allows the dimmer switch to be reset to the low-beam position whenever the headlight switch is turned to the \e1mON\e0m position. FLASHER TIMER Turn Signal Light When the ignition switch is turned to the "ON" position and turn-signal light switch is placed in the ON position for right or left turn-signaling, the system generates turn-signal light drive signals (flashing signals). The system also notifies of a blown turn signal light bulb by shortening the flashing intervals of the corresponding indicator light. Hazard Warning Light The system detects a change from OFF to ON of the hazard warning input signal and activates or shuts off the hazard warning lights accordingly. FOG LIGHT The fog light switch becomes active only when the headlights are at the low-beam mode. Therefore, if the headlights are turned off, the fog lights will also be switched off. When the headlights are turned on during the next key cycle, the fog lights will be off regardless of the fog light switch position. INTERIOR LIGHT The ETACS-ECU controls the interior lights (dome light and rear personal lights) operation as follows: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Page 2193 NOTE: Interior lights and rear personal light are controlled, only when switch position is set to the position "door controlled operation" Interior Light Dimming function When a door is opened from outside or inside [with the ignition switch turned to "LOCK" (OFF)]: When a door is opened, the ETACS-ECU causes the interior lights to be illuminated at 100% intensity. When the door is closed, it dims the interior lights to 60% intensity and approximately 30 seconds later, turns out the light completely. During this period (timer controlled period), the interior lights goes out if the ignition switch is turned "ON" or the doors are locked. - When a door is opened or closed with the ignition switch in the "ON" position: The interior lights illuminate at 100% intensity when a door is opened and turned out when it is closed. - When no door is opened and the ignition key is removed: The interior lights are illuminated at 100% intensity and turned off approximately 30 seconds later. During that time (timer-controlled period), the interior lights goes out if the ignition key is inserted and turned to "ON" or the door locking system is activated. Keyless Entry Room Lamp Answerback Interior lights's answerback operation in response to door lock control by keyless entry system: To allow the driver to confirm the doors have locked by the keyless entry system, the ETACS-ECU causes the interior lights to blink twice when the doors are locked by the RKE system and to illuminate for approximately 30 seconds when the doors are locked. The interior lights's answerback operation in response to a keyless entry system control action is accompanied by flashing of the hazard warning lights. Interior Light Automatic Shut-off Function This function prevents the battery from being discharged when the door is open or the interior lights (dome light and rear personal lights and foot lights and truck light) remains on with the ignition switch at the "LOCK" (OFF) position. The ETACS-ECU turns on its "keep" relay to switch off the battery power supply to the interior lights when the interior light loaded signal, driver's or passenger's door switches or, trunk lid latch switch remain on for approximately 30 minutes with the ignition switch ACC signal is OFF. Then the interior lights will be switched off. If the ignition switch is turned on again, the ETACS-ECU turns on its "keep" relay to illuminate the interior lights. THEFT-ALARM SYSTEM Theft-alarm System Operation If a door or hood is opened, when the theft-alarm system has been armed the horn (theft-alarm horn) will sound and headlights flash (high-beam) intermittently for a period of 180 seconds. Panic Alarm Function With the theft-alarm function armed, pressing the panic button on the keyless entry system transmitter causes the horn (theft-alarm horn and horn) to sound for about 180 seconds in an attempt to prevent theft. The alarm is turned off by pressing any switch on the transmitter. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics Information Bus: Component Tests and General Diagnostics Introduction to SWS Diagnosis INTRODUCTION TO SWS DIAGNOSIS The SWS reduces the number of wires by sending multiple signals along a single wire. This reduces vehicle weight and simplifies construction by reducing wiring harness complexity weight. The ETACS-ECU, front-ECU, column switch(incorporated in column-ECU) and sunroof motor assembly (incorporated in sunroof-ECU) have multiplex signal circuits that enable them to transmit and/or receive multiple signals and communicate with other control unit. SWS Diagnostic Troubleshooting Strategy SWS DIAGNOSTIC TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a SWS fault. 1. Gather information about the problem from the customer. 2. Verify that the condition described by the customer exists. 3. Check the vehicle for any SWS DTC. 4. If you cannot verify the condition and there are no SWS DTCs, the malfunction is intermittent. Refer to How to Use Troubleshooting/ inspection Service Points - How to Cope with Intermittent Malfunctions. See: Fundamentals and Basics 5. If you can verify the condition but there are no SWS DTCs, or the system cannot communicate with the scan tool, refer to Symptom Chart. See: Diagnosis By Symptom 6. If there is a SWS DTC, perform the diagnostic procedures for the DTC. Refer to Diagnostic Trouble Code Chart. See: Trouble Code Diagnostic Charts With Scan Tool SWS TROUBLE CODE DIAGNOSIS RETRIEVING SWS DIAGNOSTIC TROUBLE CODES Required Special Tool: MB991502: Scan Tool (MUT-11) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Use scan tool MB991502 to check for SWS diagnostic trouble codes. 3. Turn the ignition switch to the "LOCK" (OFF) position. 4. Disconnect scan tool MB991502. Without Scan Tool The manufacturer does not provide a procedure for retrieving or clearing Diagnostic Trouble Codes (DTC's) without a scan tool. Input Signal Check INPUT SIGNAL CHECK FUNCTION This mode checks the switch input signals to each ECU incorporated in the SWS. If a defect is found at this check, carry out the troubleshooting by referring to Symptom Chart. See: Diagnosis By Symptom/Input Signal Chart When Using Scan Tool MB991502 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2196 Required Special Tool: MB991502: Scan Tool (MUT-II) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. If input signal is sent to the data link connector, tone alarm of scan tool MB991502 will sound. 3. Disconnect scan tool MB991502. When Using a Voltmeter Required Special Tool - MB991529: Diagnostic Trouble Code Check Harness 1. Use special tool MB991529 to connect a voltmeter between grounded terminal 4 or 5 and ETACS-ECU terminal 9 of the 16 pin data link connector. 2. If input signal is sent to the data link connector, the voltmeter needle will fluctuate once. 3. Disconnect special tool MB991529. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2197 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2198 Requirements for which switches send input signals Diagnostic Trouble Code Chart DTC 11 DTC SET CONDITION DTC 11 is displayed when the ETACS-ECU detects an error is its own data. This fault is limited to the ETACS-ECU. TROUBLESHOOTING HINT The ETACS-ECU may be defective DIAGNOSIS Required Special Tool: MB991502; Scan Tool (MUT-II) Replace the ETACS-ECU. Confirm the DTC 11 is not displayed. DTC 12 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2199 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2200 Connectors DTC 12: Column switch fault or improper connection to the ETACS-ECU CIRCUIT OPERATION - The column switch is energized by the battery and the ignition switch (IG1). - If there is a malfunction in the battery power supply circuit, power will be supplied by the ignition switch (IG1). - If the column switch (incorporated in ECU) receives a request signal from the ETACS-ECU, the column switch will inform the SWS communication line of various switch conditions. TECHNICAL DESCRIPTION (COMMENT) The power supply circuit system of the column switch (column-ECU) may be defective. If the battery power supply circuit (terminal No.1 of the column switch) to the ECU is damaged, also check the power supply circuit from the ignition switch (IG1) (terminal No.9 of the column switch), and repair if necessary. TROUBLESHOOTING HINTS - The column switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DTC SET CONDITION DTC 12 is displayed when the column switch (incorporated in ECU) sends an abnormal signal to the ETACS-ECU. DIAGNOSIS Required Special Tools: - MB991223: Harness Set - MB991502: Scan Tool (MUT-II) STEP 1. Verify the ignition switch position. Q: Does DTC 11 set with the ignition switch at 'ON' position? YES : Go to Step 5. NO : GotoStep2. STEP 2. Check the battery power supply circuit to the column switch. Test at column switch connector C-203. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2201 1. Disconnect column switch connector C-203 and measure the voltage available at the wiring harness side. 2. Measure the voltage between terminal 1 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 8. NO : Go to Step 3. STEP 3. Check the column switch connector C-203 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is column switch connector C-203 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Confirm the DTC 12 is not displayed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2202 STEP 4. Check the wiring harness between column switch connector C-203 (terminal 1) and battery. NOTE: Also check joint connector C-141 and intermediate connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If joint connector C-141 or intermediate connector C-209 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. See: Diagrams Q: Are the wiring harness between column switch connector C-203 (terminal 1) and battery in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Confirm the DTC 12 is not displayed. See: Diagrams STEP 5. Check the ground circuit to the column switch. Test at column switch connector C-203. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2203 1. Disconnect column switch connector C-203 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance between terminal 4 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check the column switch connector C-203 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is column switch connector C-203 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. Confirm the DTC 12 is not displayed. See: Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2204 STEP 7. Check the wiring harness between column switch connector C-203 (terminal 4) and ground. NOTE: Also check joint connector C-141 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If joint connector C-141 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. See: Diagrams Q: Are the wiring harness between column switch connector C-203 (terminal 4) and ground in good condition. YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Confirm the DTC 12 is not displayed. STEP 8. Check the column switch connector C-203 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2205 pushed back in the connector. Q: Are column switch connector C-203 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection . Confirm the DTC 12 is not displayed. See: Diagrams STEP 9. Check the wiring harness between column switch connector C-203 (terminal 3) and ETACS-ECU (terminal 59) connector C-318. NOTE: Also check joint connector C-141 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If joint connector C-141 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. See: Diagrams Q: Are the wiring harness between column switch connector C-203 (terminal 3) and ETACS-ECU connector C-318 (terminal 59) in good condition? YES : Go to Step 10. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Confirm the DTC 12 is not displayed. STEP 10. Replacement of ECU. 1. Replace the column switch. 2. Confirm the DTC 12 is not displayed. Q: Does DTC 12 set? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2206 YES : Replace the ETACS-ECU. Confirm the DTC 12 is not displayed. NO : No action is necessary and testing is complete. DTC 13 DTC 13: Front-ECU fault CIRCUIT OPERATION - The power supply to the front-ECU is provided by the battery and the ignition switch (IG2). - If the power supply system from the battery is defective, the system operates by the power supply from the ignition switch (IG2). - The front-ECU communicates with other ECUs and performs control functions through the SWS communication line. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2207 DTC SET CONDITION This DTC is displayed when the front-ECU sends an abnormal signal to the ETACS-ECU. TECHNICAL DESCRIPTION (COMMENT) It is suspected that the power supply circuit to the front-ECU is defective, or the wiring harness between the SWS monitor kit and the front-ECU or their connector(s) is damaged. If the battery power supply circuit to the ECU (terminal No.7 of the front ECU) is damaged, also check the power supply circuit from the ignition switch (IG2) (terminal No.30 of the front-ECU), and repair if necessary. TROUBLESHOOTING HINTS - The front-ECU may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Harness Set - MB991502: Scan Tool (MUT-II) STEP 1. Verify the ignition switch position. Q: Does DTC 13 set with the ignition switch at "ON" position? YES: Go to Step 5. NO: Go to Step2. STEP 2. Check the battery power supply circuit to the front-ECU. Test at front-ECU connector A-10X. 1. Disconnect the front-ECU connector A-10X and measure the voltage available at the relay box side of the connector. 2. Measure the voltage between terminal 7 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2208 YES : Replace the front-ECU. Confirm the DTC 13 is not displayed. NO : Go to Step 3. STEP 3. Check the front-ECU connector A-10X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is front-ECU connector A-10X in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Confirm the DTC 13 is not displayed. See: Diagrams STEP 4. Check the wiring harness between front-ECU connector A-10X (terminal 7) and battery. Q: Is the wiring harness between front-ECU connector A-10X (terminal 7) and battery in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Confirm the DTC 13 is not displayed. STEP 5. Check the ground circuit to the front-ECU. Test at front-ECU connector A-11X. 1. Disconnect the front-ECU connector A-11X and measure the resistance available at the relay box side of the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2209 2. Measure the resistance between terminal 31 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check the front-ECU connector A-11X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is front-ECU connector A-11X in good condition? YES : Go to Step 7. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Confirm the DTC 13 is not displayed. See: Diagrams STEP 7. Check the wiring harness between front-ECU connector A-11X (terminal 31) and ground. Q: Is the wiring harness between front-ECU connector A-11X (terminal 31) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Confirm the DTC 13 is not displayed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2210 STEP 8. Check the front-ECU connector A-11X and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are front-ECU connector A-11X and ETACS-ECU connector C-318 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged components). Refer to, Harness Connector Inspection. Confirm the DTC 13 is not displayed. See: Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2211 STEP 9. Check the wiring harness between front-ECU connector A-11X (terminal 22) and ETACS-ECU (terminal 59) connector C-318. NOTE: Also check intermediate connector C-209 and joint connector C-141 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-209 and joint connector C-141 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. See: Diagrams Q: Are the wiring harness between front-ECU connector A-11X (terminal 22) and ETACS-ECU connector C-318 (terminal 59) in good condition? YES : Go to Step 10. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Confirm the DTC 13 is not displayed. STEP 10. Replacement of ECU. 1. Replace the front-ECU. 2. Confirm the DTC 13 is not displayed. Q: Does DTC 13 set? YES : Replace the ETACS-ECU. Confirm the DTC 13 is not displayed. NO : No action is necessary and testing is complete. DTC 21 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2212 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2213 Connectors DTC 21: Short Circuit Communication Line CIRCUIT OPERATION ETACS-ECU, column switch (incorporated in ECU), front-ECU and sunroof motor assembly (incorporated in ECU) communicate with each other through the SWS communication line. DTC SET CONDITION This DTC is displayed when the SWS communication line remains at low level for 0.3 seconds. No other DTC is displayed if DTC 21 is displayed. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective - The column switch may be defective - The front-ECU may be defective - The sunroof motor assembly may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Harness Set - MB991502: Scan Tool (MUT-II) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2214 STEP 1. Check the ETACS-ECU connector C-318, column switch connector C-203, front-ECU connector A-11X and sunroof motor assembly connector D-08 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are ETACS-ECU connector C-318, column switch connector C-203, front-ECU connector A-11X and sunroof motor assembly connector D-08 in good condition? YES : Go to Step 2. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. Confirm the DTC 21 is not displayed. See: Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2215 STEP 2. Check the wiring harness from ETACS-ECU connector C-318 (terminal 59) to column switch connector C-203 (terminal 3), front-ECU connector A-11X (terminal 22) and sunroof motor assembly connector D-08 (terminal 10). NOTE: Also check intermediate connectors C-28 and C-209 and joint connector C-141 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connectors C-28 and C-209 and joint connector C-141 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. See: Diagrams Q: Are the wiring harness from ETACS-ECU connector C-318 (terminal 59) to column switch connector C-203 (terminal 3), front-ECU connector A-11X (terminal 22) and sunroof motor assembly connector D-08 (terminal 10) in good condition? YES : Go to Step 3. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Confirm the DTC 21 is not displayed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2216 STEP 3. Check the column switch. Disconnect column switch connector C-203. Q: Does DTC 21 set? YES : Go to Step 4. NO (DTC 12 sets) : Replace the column switch. Confirm the DTCs 12 and 21 are not displayed. STEP 4. Check the front-ECU. Disconnect front-ECU connector A-11X. Q: Does DTC 21 set? YES : Go to Step 5. NO (DTC 13 sets): Replace the front-ECU. Confirm the DTCs 13 and 21 are not displayed. STEP 5. Check the sunroof motor assembly. Disconnect sunroof motor assembly connector D-08. Q: Does DTC 21 set? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2217 YES : Replace the ETACS-ECU. Confirm the DTC 21 is not displayed. NO : Replace the sunroof motor assembly. Confirm the DTC 21 is not displayed. Symptom Chart (Part 1) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2218 Symptom Chart (Part 2) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2219 Symptom Chart (Part 3) Input Signal Chart (Part 1) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2220 Input Signal Chart (Part 2) Inspection Procedure A-1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2221 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2222 Connectors INSPECTION PROCEDURE A-1: Scan tool MB991502 communication is not possible. CIRCUIT OPERATION The ETACS-ECU receives a diagnostic trouble code and switch signals from the data link connector. TECHNICAL DESCRIPTION (COMMENT) The wiring harness between the ETACS-ECU power supply line or the ETACS-ECU and the data link connector may be defective. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the communication with other systems. Q: Can the scan tool communicate with no systems? YES : Refer to Diagnosis. See: Testing and Inspection/Symptom Related Diagnostic Procedures NO (can not communicate with SWS only): Go to Step 2. STEP 2. Verify the ignition switch positions. Q: Can scan tool MB991502 communicate with the ETACS-ECU with the ignition switch at any position other than "ON"? YES : Go to Step 3. NO : Check the ETACS-ECU battery circuits. Refer to Inspection Procedure P-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure P-1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2223 STEP 3. Check the data link connector C-26 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are data link connector C-26 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Scan tool MB991502 should communicate with the SWS. STEP 4. Check the wiring harness between data link connector C-26 (terminal 1 and 9) and ETACS-ECU connector C-318 (terminal 67 and 51). Q: Are the wiring harness between data link connector C-26 (terminal 1 and 9) and ETACS-ECU connector C-318 (terminal 67 and 51) in good condition? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2224 YES : Go to Step 5. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Scan tool MB991502 should communicate with the SWS. STEP 5. Check the ground circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect the ETACS-ECU connector C-319 and measure at the junction block side. 2. Measure the resistance between terminal 3 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Replace the ETACS-ECU. Scan tool MB991502 should Communicate with the SWS. NO : Go to Step 6. STEP 6. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsScan tool MB991502 should communicate with the SWS. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2225 STEP 7. Check the wiring harness between ETACS-ECU connector C-319 (terminal 3) and ground. NOTE: Also check junction block connector C-308 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-308 is damaged, repair or replace it. Refer to Harness Connector Inspection. Q: Are the wiring harness between ETACS-ECU connector C-319 (terminal 3) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Scan tool MB991502 should communicate with the SWS. Inspection Procedure B-1 INSPECTION PROCEDURE B-1: Tone Alarm: Ignition key reminder tone alarm function does network normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the ignition key reminder tone alarm function, based on input signals from the following switches: - Ignition switch (IG1) - Key reminder switch Driver's door switch If the function does not work normally, a defect on the relevant circuit or the ETACS-ECU may be suspected. TROUBLESHOOTING HINTS - The key reminder switch may be defective - The driver's door switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the ETACS-ECU power supply circuit. Check that the hazard warning light illuminates when the ignition switch is in the "LOCK" (OFF) position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2226 Q: Does the hazard warning light illuminate? YES : Go to Step 2 or 3 . NO : Check the ETACS-ECU battery circuit. Refer to Inspection Procedure P-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure P-1 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Key reminder switch - Driver's door switch CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The ignition key reminder tone alarm function should work normally. NO: Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - Scan tool MB991502 does not sound when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Key reminder switch - Driver's door switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2227 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The ignition key reminder tone alarm function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - The voltmeter needle does not fluctuate when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 Inspection Procedure B-2 INSPECTION PROCEDURE B-2: Tone Alarm: Light reminder tone alarm function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the light reminder tone alarm function, based on input signals from the following switches and the front-ECU: - Ignition switch (IG1) - Driver's door switch - Taillight switch - Headlight switch If the function does not work normally, a defect on the relevant circuit or the ETACS-ECU may be suspected TROUBLESHOOTING HINTS - The driver's door switch may be defective - The column switch (turn-signal light and lighting switch) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the ETACS-ECU power supply circuit Check that the hazard warning light illuminate when the ignition switch is in the "LOCK" (OFF) position Q: Does the hazard warning light illuminate? YES : Go to Step 2 or 3 NO : Check the ETACS-ECU battery circuit. Refer to Inspection Procedure R-1. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's door switch - Taillight switch - Headlight switch CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2228 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters YES : Replace the ETACS-ECU. The light reminder tone alarm function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the lighting switch is turned from "OFF" to "TAIL":Refer to Inspection Procedure O-14 "The taillight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 - Scan tool MB991502 does not sound when the lighting switch is turned from "TAIL" to "HEAD": Refer to Inspection Procedure O-14 "The headlight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's door switch - Taillight switch - Headlight switch CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters YES : Replace the ETACS-ECU. The light reminder tone alarm function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2229 - Scan tool MB991502 does not sound when the lighting switch is turned from "OFF" to "TAIL":Refer to Inspection Procedure O-15 "The taillight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-15 - Scan tool MB991502 does not sound when the lighting switch is turned from "TAIL" to "HEAD": Refer to Inspection Procedure O-15 "The headlight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-15 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's door switch - Taillight switch - Headlight switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The light reminder tone alarm function should work normally. NO: The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the lighting switch is turned from "OFF" to "TAIL":Refer to Inspection Procedure O-14 "The taillight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 - The voltmeter needle does not fluctuate when the lighting switch is turned from "TAIL" to "HEAD":Refer to Inspection Procedure O-14 "The headlight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's door switch - Taillight switch - Headlight switch Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2230 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The light reminder tone alarm function should work normally. NO: The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the lighting switch is turned from "OFF" to "TAIL":Refer to Inspection Procedure O-15 "The taillight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-15 - The voltmeter needle does not fluctuate when the lighting switch is turned from "TAIL" to "HEAD":Refer to Inspection Procedure O-15 "The headlight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-15 Inspection Procedure B-3 INSPECTION PROCEDURE B-3: Tone alarm: Door ajar tone alarm function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the door ajar tone alarm function, based on input signals from the following switches and the front-ECU: - Ignition switch (IG1) - Driver's and passenger's door switches - Trunk lid latch switch - Speed sensor If the function does not work normally, a defect on the relevant circuit or the ETACS-ECU may be suspected. TROUBLESHOOTING HINTS - The driver's and passenger's door switches may be defective - The trunk lid latch switch may be defective - The speed sensor may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the method of the input signal Q: Which is to be used, the scan tool or the voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switches - Trunk lid latch switch - Speed sensor CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2231 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters YES : Replace the ETACS-ECU. The door ajar tone alarm function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the driver's or passenger's door is opened: Refer to Inspection Procedure 0-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - Scan tool MB991502 does not sound when the vehicle speed has reached from 24 km/h or lower to 25 km/h or higher: Refer to Inspection Procedure O-13 "The Speed Sensor signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-13 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switches - Trunk lid latch switch - Speed sensor CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters YES : Replace the ETACS-ECU. The door ajar tone alarm function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the driver's or passenger's door is opened: Refer to Inspection Procedure 0-8 "The driver's or Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2232 passenger's door switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - Scan tool MB991502 does not sound when the vehicle speed has reached from 24 km/h or lower to 25 km/h or higher: Refer to Inspection Procedure O-14 "The Speed Sensor signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switches - Trunk lid latch switch - Speed sensor 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The door ajar tone alarm function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU ." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - The voltmeter needle does not fluctuate when the vehicle speed has reached from 24 km/h or lower to 25 km/h or higher: Refer to Inspection Procedure O-13 "The Speed Sensor signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-13 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switches - Trunk lid latch switch - Speed sensor Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2233 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The door ajar tone alarm function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU ." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - The voltmeter needle does not fluctuate when the vehicle speed has reached from 24 km/h or lower to 25 km/h or higher: Refer to Inspection Procedure O-13 "The Speed Sensor signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-13 Inspection Procedure B-4 INSPECTION PROCEDURE B-4: Tone alarm: Low washer fluid level tone alarm function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the low washer fluid level tone alarm function, based on input signals from the following switches and the front-ECU: - Ignition switch (IG1) - Washer fluid level switch If the function does not work normally, a defect on the relevant circuit or the ETACS-ECU may be suspected. TROUBLESHOOTING HINTS - The speed sensor may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the method of the input signal Q: Which is to be used, the scan tool or the voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Washer fluid level switch CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2234 disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters YES : Replace the ETACS-ECU. The low washer fluid level tone alarm function should work normally. NO : - Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU". See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the windshield washer fluid level has reached from "FULL" mark to "EMPTY" mark: Refer to Inspection Procedure O-6 "The washer fluid level switch signal is not sent to the ETACS-ECU". See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-6 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IGi) - Washer fluid level switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES: Replace the ETACS-ECU. The low washer fluid level tone alarm function should work normally. NO: The voltmeter needle does not fluctuate when the ignition switch is turned from t~CC to 'ON": Refer to Inspection Procedure O-2 "The ignition switch (IGI) signal is not sent to the ETACS-ECU" See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 The voltmeter needle does not fluctuate when the windshield washer fluid level has reached from "FULL" mark to "EMPTY" mark: Refer to Inspection Procedure O-6 "The washer fluid level switch signal is not sent to the ETACS-ECU" See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-6 Inspection Procedure B-5 INSPECTION PROCEDURE B-5: Tone alarm: Seat belt tone alarm function does not work normally. TECHNICAL DESCRIPTION (COMMENT) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2235 The ETACS-ECU operates the seat belt tone alarm function, based on input signals from the following switches: - Ignition switch (IG1) - Driver's seat belt switch If the function does not work normally, a defect on the relevant circuit or the ETACS-ECU may be suspected. TROUBLESHOOTING HINTS - The driver's seat belt switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the method of the input signal Q: Which is to be used, the scan tool or the voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's seat belt switch CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters. YES : Replace the ETACS-ECU. The seat belt tone alarm function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the driver's seat belt is unfastened: Refer to Inspection Procedure O-7 "The driver's seat belt switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-7 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's seat belt switch Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2236 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The seat belt tone alarm function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the driver's seat belt is unfastened: Refer to Inspection Procedure O-7 "The driver's seat belt switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-7 Inspection Procedure B-6 INSPECTION PROCEDURE B-6: Tone alarm: Low fuel level tone alarm function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the seat belt tone alarm function, based on input signals from the following switches: - Ignition switch (IG1) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2237 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters. YES : Replace the ETACS-ECU. The low fuel level tone alarm function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the ignition switch (IG1). 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The low fuel level tone alarm function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 Inspection Procedure C-1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2238 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2239 Connectors INSPECTION PROCEDURE C-1: Central Door Locking System: Central door locking system does not operate. CIRCUIT OPERATION - The ETACS-ECU operates the door lock actuators through its dedicated relay (integrated in the ETACS-ECU). - The ETACS-ECU drives the relay to lock or unlock the door if the requirements are satisfied. TECHNICAL DESCRIPTION (COMMENT) The power supply circuit, the circuit shared by door lock actuators, or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tool: - MB991223: Harness Set Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2240 STEP 1. Check the battery power supply circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect ETACS-ECU connector C-319 and measure the voltage available at the junction block side of the connector. 2. Measure the voltage between terminal 2 and ground. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 4. NO : Go to Step 2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2241 STEP 2. Check ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. Verify that the central door locking system works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2242 STEP 3. Check the wiring harness between ETACS-ECU connector C-319 (terminal 2) and the fusible link (1). NOTE: Also check intermediate connector C-209 and junction block connector C-313 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-209 or junction block connector C-313 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2243 Q: Is the wiring harness between ETACS-ECU connector C-319 (terminal 2) and fusible link (1) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the central door locking system works normally. STEP 4. Check ETACS-ECU connector C-317 and C-319 and driver's door lock actuator connector E-13 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-317 and C-319 and driver's door lock actuator connector E-13 in good condition? YES : Go to Step 5. NO : The Wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Verify that the central door locking system works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2244 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2245 STEP 5. Check the wiring harness between ETACS-ECU connector C-317 (terminal 22) and C-319 (terminal 12) and driver's door lock actuator connector E-13 (terminals 4 and 6). NOTE: Also check intermediate connector C-211 and junction block connector C-308 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-211 or junction block connector C-308 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection?. Q: Is the wiring harness from ETACS-ECU connectors C-317 (terminal 22) and C-319 (terminal 12) to driver's door lock actuator connector E-13 (terminals 4 and 6) in good condition? YES : Replace the ETACS-ECU. Verify that the central door locking system works normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair or replace the damaged component(s). Verify that the central door locking system works normally. Inspection Procedure C-2 INSPECTION PROCEDURE C-2: Central Door Locking System: Some doors do not lock or unlock. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2246 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2247 Connectors CIRCUIT OPERATION - The ETACS-ECU operates the door lock actuators through its dedicated relay (integrated in the ETACS-ECU). - The ETACS-ECU drives the relay to lock or unlock the door if the requirements are satisfied. TECHNICAL DESCRIPTION (COMMENT) The door lock actuator, or the harness wire between ETACS-ECU and the door lock actuator may be defective. TROUBLESHOOTING HINTS - The driver's or passenger's door lock actuator may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tool: - MB991223: Test Harness Set Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2248 STEP 1. Check the location of malfunction. Q: Which door lock does not function? Driver's door : Go to Step 2. Passenger's door : Go to Step 5. STEP 2. Check the driver's door lock actuator operation. Remove the driver's door lock actuator to check. (Refer to Door-Door Handle and Latch. Q: Does the driver's door lock actuator work normally? YES : Go to Step 3. NO : Replace the driver's door lock actuator. Verify that all the doors can be locked and unlocked normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2249 STEP 3. Check ETACS-ECU connectors C-317 and C-319 and driver's door lock actuator connector E-13 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are ETACS-ECU connector C-317 and C-319 and driver's door lock actuator connector E-13 in good condition? YES : Go to Step 4. NO : Repair or check the connector. Refer to Harness Connector Inspection. Verify that all the doors can be locked and unlocked normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2250 STEP 4. Check the wiring harness between ETACS-ECU connector C-317 (terminal 22) and C-319 (terminal 12) and driver's door lock actuator connector E-13 (terminals 4 and 6). NOTE: Also check intermediate connector C-211 and junction block connector C-308 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-211 or junction block connector C-308 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection?. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2251 Q: Is the wiring harness from ETACS-ECU connectors C-317 (terminal 22) and C-319 (terminal 12) to driver's door lock actuator connector E-13 (terminals 4 and 6) in good condition? YES : Replace the ETACS-ECU. Verify that all the doors can be locked and unlocked normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the central door locking system works normally. STEP 5. Check the passenger's door lock actuator operation. Remove the passenger's door lock actuator to check. (Refer to Door - Door Handle and Latch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2252 Q: Does the passenger's door lock actuator work normally? YES : Go to Step 6. NO : Replace the passenger's door lock actuator. Verify that all the doors can be locked and unlocked normally. STEP 6. Check ETACS-ECU connector C-319 and passenger's door lock actuator connector E-07 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 and passenger's door lock actuator connector E-07 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. Verify that all the doors can be locked and unlocked normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2253 STEP 7. Check the wiring harness between ETACS-ECU connector C-319 (terminals 12 and 13) and driver's door lock actuator connector E-07 (terminals 4 and 6). NOTE: Also check intermediate connector C-213 and junction block connector C-308 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-213 or junction block connector C-308 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection?. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2254 Q: Is the wiring harness from ETACS-ECU connectors C-31 (terminals 12 and 13) to driver's door lock actuator connector E-07 (terminals 4 and 6) in good condition? YES : Replace the ETACS-ECU. Check that all the doors can be locked and unlocked normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the central door locking system works normally. Inspection Procedure C-3 INSPECTION PROCEDURE C-3: Central Door Locking System: All the doors do not lock or unlock with just the door lock switch operation. TECHNICAL DESCRIPTION (COMMENT) The door lock switch (built into the power window switch) or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The power window switch (door lock switch) may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2255 DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the defective door lock switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. All doors should be locked or unlocked by using the door lock switch. NO : Scan tool MB991502 does not sound when the door lock switch is turned from "OFF" to "LOCK" or "UNLOCK": Refer to Inspection Procedure O-11 "The door lock switch (incorporated in power window main switch and power window sub-switch) signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the defective door lock switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. All doors should be locked or unlocked by using the door lock switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2256 NO : The voltmeter needle does not fluctuate when the door lock switch is turned from "OFF" to "LOCK" or "UNLOCK": Refer to Inspection Procedure O-11 "The door lock switch (incorporated in power window main switch and power window sub-switch) signal is not sent to the ETACS-ECU. Inspection Procedure C-4 INSPECTION PROCEDURE C-4: Central Door Locking System: All the doors do not lock or unlock with just the door lock key cylinder key Operation. TECHNICAL DESCRIPTION (COMMENT) The door lock key cylinder switch or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The door lock key cylinder switch may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the defective door lock key cylinder switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. All doors should be locked or unlocked by using the door lock key cylinder switch. NO : Scan tool MB991502 does not sound when the driver's or passenger's door lock key cylinder is turned from the neutral (off) position to "LOCK" or "UNLOCK": Refer to Inspection Procedure O-9 "The driver's or passenger's door lock key cylinder switch signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signal from the defective door lock key cylinder switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2257 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. All doors should be locked or unlocked by using the door lock key cylinder switch. NO : The voltmeter needle does not fluctuate when the driver-s or passenger's door lock key cylinder is turned from the neutral (off) position to "LOCK" or "UNLOCK": Refer to Inspection Procedure O-11 "The door lock switch (incorporated in power window main switch and power sub-switch) signal is not sent to the ETACS-ECU. Inspection Procedure C-5 INSPECTION PROCEDURE C-5: Central Door Locking System: All the doors do not lock with just the driver's inside lock knob lock operation. TECHNICAL DESCRIPTION (COMMENT) The driver's door lock actuator switch or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The driver's door lock actuator switch may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the driver's door lock actuator switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2258 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. All doors should be locked by using the driver's inside lock knob. NO : Scan tool MB991502 does not sound when the driver's inside lock knob is locked or unlocked: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signal from the driver's door lock actuator switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. All doors should be locked by using the driver's inside lock knob. NO : The voltmeter needle does not fluctuate when the driver's inside lock knob is locked or unlocked: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." Inspection Procedure C-6 INSPECTION PROCEDURE C-6: Central Door Locking System: Forgotten key prevention function does not operate. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the forgotten key prevention function, based on the input signals from the following switches: - Key reminder switch - Driver's or passenger's door switch - Driver's or passenger's door lock actuator switch If the function does not work normally, a defect on the relevant circuit or the ETACS-ECU may be suspected. TROUBLESHOOTING HINTS - The key reminder switch may be defective. - The driver's or passenger's door switch may be defective. - The driver's or passenger's door lock actuator switch may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2259 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Key reminder switch - Driver's and passenger's door switch - Driver's and passenger's door lock actuator switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The forgotten key prevention function should work normally. NO : Scan tool MB991502 does not sound when the ignition key is removed from the ignition key cylinder: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the driver's inside lock knob is locked or unlocked: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Key reminder switch - Driver's and passenger's door switch - Driver's and passenger's door lock actuator switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The forgotten key prevention function should work normally. NO : Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2260 - The voltmeter needle does not fluctuate when the ignition key is removed from the ignition key cylinder: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the driver's inside lock knob is locked or unlocked: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU. Inspection Procedure C-7 INSPECTION PROCEDURE C-7: Central Door Locking System: Rolling lock function does not operate. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the rolling lock function, based on the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switch - Driver's or passenger's door lock actuator switch - Speed sensor If the function does not work normally/a defect on the relevant circuit or the ETACS-ECU may be suspected. TROUBLESHOOTING HINTS - The driver's or passenger's door switch may be defective. - The driver's or passenger's door lock actuator switch may be defective. - The speed sensor may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switch - Driver's and passenger's door lock actuator switch - Speed sensor CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2261 Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The rolling lock function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the driver's inside lock knob is locked or unlocked: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the vehicle speed exceeds 24km/h (14.9 mph): Refer to Inspection Procedure O-13 "The speed sensor signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switch - Driver's and passenger's door lock actuator switch - Speed sensor 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The rolling lock function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON"; Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the driver's inside lock knob is locked or unlocked: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the vehicle speed exceeds 24km/h (14.9 mph): Refer to Inspection Procedure O-13 "The speed sensor signal is not sent to the ETACS-ECU." Inspection Procedure D-1 INSPECTION PROCEDURE D-1: Power Window Relay: Power windows do not work at all. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2262 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2263 Connectors CIRCUIT OPERATION The ETACS-ECU turns ON the power window relay when the ignition switch (IG1) is ON. TECHNICAL DESCRIPTION (COMMENT) The power window relay or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The power window relay may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2264 STEP 1. Check the power window relay. Q: Is the power window relay in good condition? YES : Go to Step 2 or Step 3 . NO : Replace the power window relay. The power windows function should work now normally. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the ignition switch (IG1). CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2265 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the ignition switch (IG1). 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." STEP 4. Check the battery power supply circuit to the power window relay. Test at power window relay connector C-316. 1. Disconnect power window relay connector C-316 and measure the voltage available at the junction block side of the connector. 2. Measure the voltage between terminal 5 and ground. - The voltage should measure approximately 12 volts (battery positive voltage). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2266 Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 7. NO : Go to Step 5. STEP 5. Check power window relay connector C-316 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is power window relay connector C-316 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The power windows function should work now normally. STEP 6. Check the wiring harness between power window relay connector C-316 (terminal 5) and fusible link (5). NOTE: Also check junction block connector C-310 and intermediate connector C-209 for loose, corroded or damaged terminals, or terminals pushed Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2267 back in the connectors. If junction block connector C-310 or intermediate connector C-209 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between power window relay connector C-316 (terminal 5) and fusible link (5) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The power windows function should work now normally. STEP 7. Check the ground circuit to the power window relay. Test at power window relay connector C-316. 1. Disconnect power window relay connector C-316 and measure the resistance available at the junction block side of the connector. 2. Measure the resistance value between terminal 3 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2268 YES : Go to Step 10. NO : Go to Step 8. STEP 8. Check power window relay connector C-316 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is power window relay connector C-316 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The power windows function should work now normally. STEP 9. Check the wiring harness between power window relay connector C-316 (terminal 3) and ground. NOTE: Also check junction block connector C-308 for loose, corroded or damaged terminals, or terminals pushed back in the connector. If junction block connector C-308 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between power window relay connector C-316 (terminal 3) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The power windows function should work now normally. STEP 10. Check the ground circuit to the power window main switch. Test at power window main switch connector E-12. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2269 1. Disconnect power window main switch connector E-12 and measure the resistance available at the harness side of the connector. 2. Measure the resistance value between terminal9 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 13. NO: Go to Step 11. STEP 11. Check power window main switch connector E-12 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is power window main switch connector E-12 in good condition? YES: Go to Step 12. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The power windows function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2270 STEP 12. Check the wiring harness between power window main switch E-12 (terminal 9) and ground. NOTE: Also check intermediate connector C-211 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If intermediate connector C-211 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between power window main switch connector E-12 (terminal 9) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The power windows function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2271 STEP 13. Check power window relay connector C-316 and ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window relay connector C-316 and ETACS-ECU connector C-319 in good condition? YES: Go to Step 14. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The power windows function should work now normally. STEP 14. Check the battery power supply circuit to the power window main switch. Test at power window main switch connector E-12. 1. Disconnect power window main switch connector E-12 and measure the voltage available at the harness side of the connector. 2. Turn the ignition switch to "ON" position. 3. Measure the voltage between terminal 6 and ground. - The voltage should measure approximately 12 volts (battery positive voltage). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2272 Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the power window main switch. The power windows function should work now normally. NO: Go to Step 15. STEP 15. Check power window relay connector C-316 and power window main switch connector E-12 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window relay connector C-316 and power window main switch connector E-12 in good condition? YES: Go to Step 16. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The power windows function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2273 STEP 16. Check the wiring harness between power window relay connector C-316 (terminal 4) and power window main switch connector E-12 (terminal 6). NOTE: Also check intermediate connector C-211 and junction block connector C-311 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If intermediate connector C-211 or junction block connector C-311 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between power window relay connector C-316 (terminal 4) and power window main switch connector E-12 (terminal 6) in good condition? YES : Replace the ETACS-ECU. The power windows function should work now normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The power windows function should work now normally. Inspection Procedure D-2 INSPECTION PROCEDURE D-2: Power Window Relay: Power window timer function does not work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2274 TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the power window timer function, based on input signals from the following switches: - Ignition switch (IG1) - Driver's or passenger's door switch If the power window timer function do not work normally, the input signal circuit or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The driver's or passenger's door switch may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal. Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switches CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The power window timer function should work normally. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switches Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2275 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The power window timer function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU. Inspection Procedure D-3 INSPECTION PROCEDURE D-3: Power Window Relay: Only driver's power window does not work by operating power window main switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2276 CIRCUIT OPERATION The power window motor (LH)opens or closes the door window (LH) when the power window main switch is moved to "UP" or "DOWN" position. The driver's window switch is different from the other window switches. The driver's switch contains a processor to assist with "UP" and "DOWN" function of the window. TECHNICAL DESCRIPTION (COMMENT) The power window main switch or the power window motor (LH) may be detective. TROUBLESHOOTING HINTS - The power window main switch may be defective. - The power window motor (LH) may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2277 Required Special Tool: - MB991223: Test Harness Set STEP 1. Check the power window motor (LH) operation. 1. Remove the power window motor (LH). (Refer to 8S, Door Glass and Regulator.) 2. Connect a battery directly to the motor terminals and check that the motor runs smoothly. Q: Is the power window motor (LH) in good condition? YES : Go to Step 2. NO : Replace the front power window motor (LH). The power window (LH) function should work now normally. STEP 2. Check power Window main switch connector E-12 and front power window motor (LH)connector E-11 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window main switch connector E-12 and front power window motor (LH) connector E-11 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The power window (LH) function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2278 STEP 3. Check the wiring harness between power window main switch connector E-12 (terminals 1 and 5) and front power window motor (LH) connector E-11 (terminals 1 and 2). Q: Is the wiring harness between power window main switch connector E-12 (terminals 1 and 5) and front power window motor (LH) connector E-11 (terminals 1 and 2) in good condition? YES : Replace the power window main switch. Check that the power window (LH) function normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back In the connector. Repair the wiring harness as necessary. The power window (LH) function should work now normally. Inspection Procedure D-4 INSPECTION PROCEDURE D-4: Power Window Relay: Power window do not work normally by operating the passenger's power window sub switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2279 Connectors Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2280 CIRCUIT OPERATION Power window motor open or close the door window when the passenger's sub-switch is moved to "UP" or "DOWN" position. TECHNICAL DESCRIPTION (COMMENT) A power window sub-switch or power window motor may be defective. Alternatively, the power window lock switch (incorporated in the power window main switch) may remain pressed to "LOCK" position. TROUBLESHOOTING HINTS - The power window main switch may be defective. - The power window sub-switch may be defective. - The power window motor (RH) may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tool: - MB991223: Test Harness Set STEP 1. Check the power window lock switch. Q: Is the power window lock switch at the "UNLOCK" position? YES : Go to Step 2. NO : Move the power window lock switch to the "UNLOCK" position. The power window sub-switches is operated, the front passenger's power window function should now work normally. STEP 2. Check the power window main switch continuity. 1. Remove the power window main switch. (Refer to Door Trim.) 2. Check continuity when the switch on the power window main switch is operated to "UP" or "DOWN" position. Q: Is the power window main switch in good condition? YES : Go to Step 3. NO : Replace the power window main switch. The power window sub-switches is operated, the passenger's power window function should now Work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2281 STEP 3. Check the power window sub-switch continuity. 1. Remove the power window sub-switch. (Refer to Door Trim.) 2. Check continuity when the power window sub-switch is operated to "UP" or "DOWN" position. Q: Is the power window sub-switch in good condition? YES : Go to Step 4. NO : Replace the power window sub-switch. The passenger's power window function should work now normally. STEP 4. Check the power window motor (RH) operation. 1. Remove the power window regulator (RH). (Refer to Door Glass and Regulator.) 2. Follow the table below to check the power window motor (RH) for correct operation. Q: Is the power window motor (RH) in good condition? YES : Go to Step 5. NO : Replace the power regulator assembly (RH). The passenger's power window function should work now normally. STEP 5. Check the battery power supply circuit to the power window sub-switch. Test at power window sub-switch connector E-05. 1. Disconnect power window sub-switch connector E-05 and measure the voltage available at the harness side of the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2282 2. Measure the voltage between terminal 7 and ground. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check power window main switch connector E-12 and power window sub-switch connector E-05 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window main switch connector E-12 and power window sub-switch connector E-05 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The passenger's power window function should work now normally. STEP 7. Check the wiring harness between power window main switch connector E-12 (terminal 2) and power window sub-switch connector E-05 (terminal 7). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2283 NOTE: Also check intermediate connectors C-211 and C-213 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If intermediate connector C-211 or C-213 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2284 Q: Is the wiring harness between power window main switch connector E-12 (terminal 2) and power window sub-switch connector E-05 (terminal 7) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The passenger's power window function should work now normally. STEP 8. Check the ground circuit to the power window sub-switch. Test at power window sub-switch connector E-05. 1. Disconnect power window sub-switch connector E-05 and measure the resistance available at the harness side of the connector. 2. Measure the resistance value between terminal 5 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 11. NO : Go to Step 9. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2285 STEP 9. Check power window main switch connector E-12 and power window sub-switch connector E-05 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window main switch connector E-12 and power window sub-switch connector E-05 in good condition? YES : Go to Step 10. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The passenger's power window function should work now normally. STEP-10, Check the wiring harness between power Window main switch connector E-12 (terminal 8) and power window sub-switch connector E-05 (terminal 5). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2286 NOTE: Also check intermediate connectors C-211 and C-213 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If intermediate connector C-211 or C-213 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection Q: Is the wiring harness between power window main switch connector E-12 (terminal 8) and power sub-switch connector E-05 (terminal 5) in good condition? YES : Replace the power window main switch. The passenger's power window function should work now normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The passenger's power window function should work now normally. STEP 11. Check the ground circuit to the power window sub-switch. Test at power window sub-switch connector E-05. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2287 1. Disconnect power window sub-switch connector E-05 and measure the resistance available at the harness side of the connector. 2. Measure the resistance value between terminal 8 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 14. NO: Go to Step 12. STEP 12. Check power window main switch connector E-12 and power window sub-switch connector E-05 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window main switch connector E-12 and power window sub-switch connector E-05 in good condition? YES : Go to Step 13. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2288 NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The passenger's power window function should work now normally. STEP 13. Check the wiring harness between power window main switch connector E-12 (terminal 7) and power window sub-switch connector E-05 (terminal 8). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2289 NOTE: Also check intermediate connectors C-211 and C-213 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If intermediate connector C-211 or C-213 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between power window main switch connector E-12 (terminal 7) and power sub-switch connector E-05 (terminal 8) in good condition? YES : Replace the power window main switch. When the power window sub-switch is operated, the passenger's power window should open or close normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The passenger's power window function should work now normally. STEP 14. Check power window sub-switch connector E-05 and power window motor (RH) connector E-04 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window sub-switch connector E-05 and power window motor (RH) connector E-04 in good condition? YES : Go to Step 15. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2290 NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The passenger's power window function should work now normally. STEP 15. Check the wiring harness between power window sub-switch connector E-05 (terminals 5 and 8) and power window motor (RH) connector E-04 (terminals 2 and 1). Q: Is the wiring harness between power window sub-switch connector E-05 (terminals 5 and 8) and power window motor (RH) connector E-04 (terminals 2 and 1) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The passenger's power window function should work now normally. Inspection Procedure D-5 INSPECTION PROCEDURE D-5: Power Window Relay: Passenger's window do not work normally by operating the power window main switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2291 CIRCUIT OPERATION The power window motor (RH) opens or closes the power window (RH) when the passenger's power switch of the power window main switch is moved to "UP" or "DOWN" position. TECHNICAL DESCRIPTION (COMMENT) If the power window (RH) opens and closes normally when the power window sub-switch is moved to "UP" or "DOWN" position, the power window main switch may be defective. TROUBLESHOOTING HINT - The power window main switch may be defective. STEP 1. Check that power window sub-switch operate normally. Q: Power window (RH) can not work by means of the power window main switch. But, can you operate the power window (RH) by means of the corresponding power window sub-switch? YES : Replace the power window main switch. NO : Repair the power window (RH) so that it can be operated by means of the power window sub-switch. Refer to Inspection Procedure D-4 "Power window do not work normally by operating the passenger's power window sub-switch Inspection Procedure E-1 INSPECTION PROCEDURE E-1: Keyless Entry System: Keyless entry system does not operate. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2292 CIRCUIT OPERATION Receiver within the ETACS-ECU receives the lock/ unlock/trunk signal from the transmitter. TECHNICAL DESCRIPTION (COMMENT) The cause may be a malfunction of the receiver and transmitter communication system. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective. - The transmitter may be defective. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness. STEP 1. Check the central door locking system operation. Q: Does the central door locking system work normally? YES : Go to Step 2 or Step 3 . NO : Carry out the troubleshooting by referring the Symptom Chart. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the transmitter switches. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2293 YES : Replace the ETACS-ECU. All the doors should be locked or unlocked by using the transmitter. NO : Scan tool MB991502 does not sound when the transmitter switch "LOCK", "UNLOCK" or "TRUNK" button is depressed: Refer to Inspection Procedure O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the transmitter switches. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. All the doors should be locked or unlocked by using the transmitter. NO : The voltmeter needle does not fluctuate when the transmitter switch "LOCK", "UNLOCK" or "TRUNK" button is depressed: Refer to Inspection Procedure O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU Inspection Procedure E-2 INSPECTION PROCEDURE E-2: Keyless Entry System: The interior lights, the hazard warning lights and the horn do not operate through the answerback function. TECHNICAL DESCRIPTION (COMMENT) The turn-signal light and the horn answerback functions can be selected by the driver's desire (can be deactivated). However, the interior lights answerback function can not be deactivated. If all of these devices do not operate through the answerback function, the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - .The turn-signal light may be defective. - the theft-alarm horn may be defective. - The interior lights may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the answerback set condition. Activate the answerback functions. (Refer to Keyless Entry System - On-vehicle Service - Enabling/ disabling the Answerback Function.) Q: Does the answerback function work normally? YES : No action is necessary and testing is complete. NO : Go to Step 2. STEP 2. Retest the system. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2294 Q: Which components) does not operate through the answerback? - Only the interior lights : Go to Step 3. - Only the hazard warning lights : Go to Step 4. - Only the horn : Go to Step 5. None of the interior lights, the turn-signal lights, and the horn : Replace the ETACS-ECU. The answerback function should work normally. STEP 3. Check the interior lights dimming function. Q: Does the interior lights dimming function work normally? YES : Replace the ETACS-ECU. The answerback function should work normally. NO : Refer to Inspection Procedure M-2 "Interior light dimming function does not work normally." STEP 4. Check the hazard warning light operation. Q: Do the hazard warning lights operate normally? YES : Replace the ETACS-ECU. The answerback function should work normally. NO : Refer to Inspection Procedure K-2 "Hazard warning lights do not flash when the hazard warning light switch is turned on." STEP 5. Check the working of the horn by the theft-alarm system. Q: Does the horn work normally by the theft-alarm system? YES : Replace the ETACS-ECU. The answerback function should work normally. NO : Refer to Inspection Procedure N-2 "Horn does not sound when the theft-alarm system is triggered Inspection Procedure E-3 INSPECTION PROCEDURE E-3: Keyless Entry System: Trunk lid opener function does not work. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2295 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2296 Connectors CIRCUIT OPERATION If trunk lid opener signal is input from transmitter, ETACS-ECU makes trunk lid opener actuator open the trunk lid. TECHNICAL DESCRIPTION (COMMENT) If door lock or unlock operation is correctly done by the transmitter, the cause is a malfunction of trunk lid opener actuator or ETACS-ECU. TROUBLESHOOTING HINTS - The trunk lid opener actuator may be defective. - The transmitter may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the keyless entry system operation (door lock and unlock operation). Q: Does the keyless entry system door lock and unlock operation work normally? YES : Go to Step 2 or Step 3 . NO : Solve the problem first. Refer to Inspection Procedure E-1 "Keyless entry system does not operate." STEP 2. Check the input signal (by using scan tool MB991502). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2297 Check the input signals from the following switches: - Trunk lid latch switch - transmitter switches CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the transmitter switch "LOCK", "UNLOCK" or "TRUNK" button is depressed: Refer to Inspection Procedure O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Trunk lid latch switch - transmitter switches 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure 0-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the transmitter switch "LOCK", "UNLOCK" or "TRUNK" button is depressed: Refer to Inspection Procedure O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU." STEP 4. Check the trunk lid opener actuator assembly operation. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2298 1. Remove the trunk lid opener actuator assembly. Refer to Trunk Lid. 2. Check that the trunk lid opener actuator assembly lever function. Q: Is the trunk lid opener actuator assembly in good condition? YES : Go to Step 5. NO : Replace the trunk lid latch assembly. Refer to Trunk Lid. Verify that the trunk lid opener actuator assembly works normally. STEP 5. Check the ground circuit to the trunk lid opener actuator assembly. Test at trunk lid opener actuator assembly connector F-04. 1. Disconnect trunk lid opener actuator assembly connector F-04 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance value between terminal 2 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check trunk lid opener actuator assembly connector F-04 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is trunk lid opener actuator assembly connector F-04 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. Verify that the trunk lid opener works normally. STEP 7. Check the wiring harness between trunk lid opener actuator connector F-04 (terminal 2) and ground. Q: Is the wiring harness between trunk lid opener actuator connector F-04 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the trunk lid opener works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2299 STEP 8. Check trunk lid opener actuator assembly connector F-04 and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are trunk lid opener actuator connector F-04 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Verify that the trunk lid opener works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2300 STEP 9. Check the wiring harness between trunk lid actuator opener assembly connector F-04 (terminal 1) and ETACS-ECU connector C-317 (terminal 32). NOTE: Also check intermediate connector C-210 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-210 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between trunk lid actuator opener assembly connector F-04 (terminal 1) and ETACS-ECU connector C-317 (terminal 32) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the trunk lid opener works normally. Inspection Procedure E-4 INSPECTION PROCEDURE E-4: Keyless Entry System: Encrypted code cannot be registered. TECHNICAL DESCRIPTION (COMMENT) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2301 The ETACS-ECU activates the encrypted code register mode according to the following switch signals: - Key reminder switch - Hazard warning light switch If the encrypted code register mode is not set, the relevant input signal circuit or the ETACS-ECU may be defective. If a transmitter can not be registered although the encrypted code register mode is set, the transmitter or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The key reminder switch may be defective. - The hazard warning light switch may be defective. - The transmitter may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the trouble symptom. Q: Is the encrypted code register mode set? YES : Go to Step 4. NO : Go to Step 2 or Step 3 . STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Key reminder switch - Hazard warning light switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. Check that the transmitter can be registered. NO : Scan tool MB991502 does not sound when the ignition key is removed from the ignition key cylinder: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the hazard warning light switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-4 "The hazard warning light switch signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Key reminder switch Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2302 - Hazard warning light switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. Check that the transmitter can be registered. NO : The voltmeter needle does not fluctuate when the ignition key is removed from the ignition key cylinder: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the hazard warning light switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-4 "The hazard warning light switch signal is not sent to the ETACS-ECU." STEP 4. Check the transmitter. Q: Can the encrypted code be registered after the transmitter battery has been renewed? YES : No action is necessary and testing is complete. NO : Replace the transmitter. If the transmitter can not be registered even if the transmitter has been replaced, replace the ETACS-ECU. Check that the transmitter can be registered. Inspection Procedure F-1 INSPECTION PROCEDURE F-1: Sunroof: Sunroof does not operate. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2303 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2304 Connectors CIRCUIT OPERATION - The sunroof motor assembly is energized by the battery through fusible link (5) and battery. - If the ignition switch (IG2) sends a signal, the sunroof motor assembly operates. TECHNICAL DESCRIPTION (COMMENT) The power supply circuit of the sunroof motor assembly, the sunroof switch ground circuit, or the sunroof motor assembly may be defective. TROUBLESHOOTING HINTS - The sunroof switch may be defective. - The sunroof motor assembly may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tool: - MB991223: Test Harness Set STEP 1. Check the battery power supply circuit to the sunroof motor assembly. Test at sunroof motor assembly connector D-08 by backprobing. 1. Measure the voltage available at the harness side of sunroof motor assembly connector D-08 without disconnecting sunroof motor assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2305 2. Measure the voltage between terminal 1 and ground by backprobing. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 4. NO : Go to Step 2. STEP 2. Check sunroof motor assembly connector D-08 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is the sunroof motor assembly connector D-08 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The sunroof function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2306 STEP 3. Check the wiring harness between sunroof motor assembly connector D-08 (terminal 1) and fusible link (5). NOTE: Also check intermediate connectors C-28 and C-209 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If intermediate connector C-28 or C-209 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between sunroof motor assembly connector D-08 (terminal 1) and fusible link (5) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The sunroof function should work now normally. STEP 4. Check the battery power supply circuit to the sunroof motor assembly. Test at sunroof motor assembly connector D-08 by backprobing. 1. Measure the voltage available at the harness side of sunroof motor assembly connector D-08 without disconnecting sunroof motor assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2307 2. Measure the voltage between terminal 3 and ground by backprobing. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 7. NO : Go to Step 5. STEP 5. Check sunroof motor assembly connector D-08 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is the sunroof motor assembly connector D-08 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The sunroof function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2308 STEP 6. Check the wiring harness between sunroof motor assembly connector D-08 (terminal 3) and battery. NOTE: Also check intermediate connectors C-28, C-141 and C-209 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If intermediate connector C-28, C-141 or C-209 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between sunroof motor assembly connector C-08 (terminal 3) and battery in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Check that the sunroof function should work now normally. STEP 7. Check the battery power supply circuit to the sunroof motor assembly. Test at sunroof motor assembly connector D-08 by backprobing. 1. Measure the voltage available at the harness side of sunroof motor assembly connector D-08 without disconnecting sunroof motor assembly. 2. Turn the ignition switch to "ON" position. 3. Measure the voltage between terminal 2 and ground by backprobing. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 10. NO : Go to Step 8. STEP 8. Check sunroof motor assembly connector D-08 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2309 Q: Is the sunroof motor assembly connector D-08 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The sunroof function should work now normally. STEP 9. Check the wiring harness between sunroof motor assembly connector D-08 (terminal 2) and ignition switch (IG2). NOTE: Also check junction block connectors C-302 and C-311 for loose, corroded or damaged terminals, or terminals pushed back in the connectors. If junction block connector C-302 or C-311 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between sunroof motor assembly connector C-08 (terminal 2) and ignition switch (IG2) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Check that the sunroof function should work now normally. STEP 10. Check the ground circuit to the sunroof motor assembly. Test at sunroof motor assembly connector D-08 by backprobing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2310 1. Measure the resistance available at the harness side of sunroof motor assembly connector D-08 without disconnecting sunroof motor assembly. 2. Measure the resistance between terminal 5, 9 and ground by backprobing. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 13. NO: Go to Step 11. STEP 11. Check sunroof motor assembly connector D-08 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is the sunroof motor assembly connector D-08 in good condition? YES : Go to Step 12. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The sunroof function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2311 STEP 12. Check the wiring harness between sunroof motor assembly connector D-08 (terminals 5 and 9) and ground. Q: Is the wiring harness between sunroof motor assembly connector D-08 (terminals 5 and 9) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The sunroof function should work now normally. STEP 13. Check the sunroof switch. Q: Does the check above meet the values in the table? YES: Go to Step 14. NO : Replace the sunroof switch. The sunroof function should work now normally. STEP 14. Check the ground circuit to the sunroof switch. Test at sunroof switch connector D-07. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2312 1. Disconnect the sunroof switch connector D-07 and measure at the harness side. 2. Measure the resistance between terminal 2 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES: Go to Step 17. NO: Go to Step 15. STEP 15. Check sunroof switch connector D-07 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is the sunroof switch connector D-07 in good condition? YES: Go to Step 16. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The sunroof function should work now normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2313 STEP 16. Check the wiring harness between sunroof switch connector D-07 (terminal 2) and ground. Q: Is the wiring harness between sunroof switch connector D-07 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The sunroof function should work now normally. STEP 17. Check the sunroof switch connector D-07 and sunroof motor assembly connector D-08 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is sunroof switch connector D-07 and sunroof motor assembly connector D-08 in good condition? YES : Replace the sunroof motor assembly. The sunroof function should work now normally. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The sunroof function should work now normally. Inspection Procedure F-2 INSPECTION PROCEDURE F-2: Sunroof: Any of the sunroof switch positions is defective. TECHNICAL DESCRIPTION (COMMENT) The sunroof switch or the sunroof motor assembly may be defective. TROUBLESHOOTING HINTS - The sunroof switch may be defective. - The sunroof motor assembly may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2314 DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal. Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (using the scan tool MB991502). Check the input signals from the sunroof switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "'LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the sunroof motor assembly. The sunroof should work normally in all of the switch positions. NO : Scan tool MB991502 does not sound when the sunroof switch is turned from "OFF" to "OPEN/TILT UP" or "CLOSE/TILT DOWN": Refer to Inspection Procedure O-18 "The open/tilt up or close/tilt down switch signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the sunroof switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the sunroof motor assembly. The sunroof should work normally in all of the switch positions. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2315 NO : Scan tool MB991502 does not sound when the sunroof switch is turned from "OFF" to "OPEN/TILT UP" or "CLOSE/TILT DOWN": Refer to Inspection Procedure O-18 "The open/tilt up or close/tilt down switch signal is not sent to the ETACS-ECU." Inspection Procedure F-3 INSPECTION PROCEDURE F-3: Sunroof: Sunroof timer function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The sunroof motor assembly deactivates the sunroof timer if the SWS communication line is open circuited. In addition, when the doors are opened if the door switch circuit is defective and the timer is on, the sunroof timer should not operate normally. TROUBLESHOOTING HINTS - The driver's or passenger's door switch may be defective. - The sunroof motor assembly may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the in put signal. Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502: Go to Step 2. Voltmeter: Go to Step 3. STEP 2. Check the input signal (by using the scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switch - Sunroof switch NOTE: If can be determined whether the wiring harness Between the sunroof motor assembly and the ETACS-ECU is defective or not by checking the SWS communication line. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the sunroof motor assembly. The sunroof timer function should work normally. NO: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2316 - Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU. - Scan tool MB991502 does not sound when the driver's or passenger's door is opened: Refer to Inspection :Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." - Scan tool MB9915O2 does not sound when the sunroof switch is turned from "0FF" to "OPEN/TILT UP" or "CLOSE/TILT DOWN": Refer to Inspection Procedure O-19 "The Open/tilt up or close/tilt down switch signal is not sent to the ETACS-ECU. STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's and passenger's door switch - Sunroof switch NOTE: It can be determined whether the wiring harness between the sunroof motor assembly and the ETACS-ECU is defective or not by checking the SWS communication line. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the sunroof motor assembly. The sunroof timer function should work normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the sunroof switch is turned from "OFF" to "OPEN/ TILT UP" or "CLOSE/TILT DOWN": Refer to Inspection Procedure O-19 "The open/tilt up or close/tilt down switch signal is not sent to the ETACS-ECU." Inspection Procedure F-4 INSPECTION PROCEDURE F-4: Sunroof: Safety mechanism does not function. TECHNICAL DESCRIPTION (COMMENT) The sunroof motor assembly monitors load condition according to the current, which runs in the motor. If the motor current exceeds a predetermined value, the sunroof motor reverses due to safety mechanism. If the sunroof motor does not reverse when an excessive load is applied, the sunroof motor assembly may be defective. TROUBLESHOOTING HINT The sunroof motor assembly may be defective. DIAGNOSIS Replace the sunroof motor assembly. The sunroof safety mechanism should work normally. Inspection Procedure G-1 INSPECTION PROCEDURE G-1: Windshield Wiper and Washer: Windshield wiper does not operate. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2317 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2318 Connectors CIRCUIT OPERATION - A signal from the windshield wiper switch is sent through the column-ECU inside the column switch to the front-ECU. The signal turns on the relay inside the front-ECU to operate the windshield wiper motor. - If the SWS communication line is defective, another signal line (wiper back-up circuit) will be active. In that case, the windshield wiper will operate at low-speed when the windshield wiper switch is in the "LO" or "HIGH" position. TECHNICAL DESCRIPTION (COMMENT) If the windshield wiper does not work at all, the windshield wiper motor, column switch (windshield wiper and washer switch) or the front-ECU may be defective. TROUBLESHOOTING HINTS - The windshield wiper motor may be defective. - The column switch (windshield wiper and washer switch) may be defective. - The front-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2319 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the windshield wiper switches. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sounds when the input signal enters? YES : Go to Step 4 NO : Scan tool MB991502 does not sound when the windshield wiper switch is turned from "OFF" to "MIST", "INT", "LO" or "HIGH": Refer to Inspection Procedure O-16 "The windshield mist wiper switch, windshield intermittent wiper switch, windshield low-speed wiper switch, windshield high-speed wiper switch or windshield washer switch signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the windshield wiper switches. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the windshield wiper switch is turned from "OFF" to "MIST", "INT", "LO" or "HIGH": Refer to Inspection Procedure O-16 "The windshield mist wiper switch, windshield intermittent wiper switch, windshield low-speed wiper switch, windshield high-speed wiper switch or windshield washer switch signal is not sent to the ETACS-ECU." STEP 4. Check the windshield wiper motor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2320 1. Disconnect the windshield wiper motor connector A-03. 2. Connect a battery to the windshield wiper motor as shown. Then check the windshield wiper motor operates normally at high and low speeds. Q: Is the wiper motor in good condition? YES : Go to Step 5. NO : Replace the windshield wiper motor. Verify that the windshield wiper works normally. STEP 5. Check the ground circuit to the windshield wiper motor. Test at the windshield wiper motor connector A-03. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2321 1. Disconnect windshield wiper motor connector A-03 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance value between terminal 5 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check windshield wiper motor connector A-03 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is windshield wiper motor connector A-03 in good condition? YES : Go to Step 7. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2322 NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Verify that the windshield wiper works normally. STEP 7. Check the wiring harness between windshield wiper motor connector A-03 (terminal 5) and ground. Q: Is the wiring harness between windshield wiper motor connector A-03 (terminal 5) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the windshield wiper works normally. STEP 8. Check the ignition switch (ACC) circuit to the front-ECU. Test at front-ECU connector A-11X. 1. Disconnect front-ECU connector A-11X and measure the voltage available at the relay box side of the connector. 2. Turn the ignition switch to "ACC" position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2323 3. Measure the voltage between terminal 24 and ground. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the front-ECU. The windshield wiper should work normally. NO : Go to Step 9. STEP 9. Check the front-ECU connector A-11X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is front-ECU connector A-11X in good condition? YES : Go to Step 10. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Verify that the windshield wiper works normally. STEP 10. Check the wiring harness between front-ECU connector A-11X (terminal 24) and the ignition switch (ACC). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2324 NOTE: Also check intermediate connector C-209, junction block connectors C-311 and C-312 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-209, junction block connector C-311 or C-312 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between front-ECU connector A-11X (terminal 24) and the ignition switch (ACC) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the windshield wiper works normally. Inspection Procedure G-2 INSPECTION PROCEDURE G-2: Windshield Wiper and Washer: Any of the windshield wiper switch positions is defective. WINDSHIELD WIPER MOTOR DRIVE CIRCUIT - Refer to Inspection Procedure G-1 "Windshield wiper does not operate." CIRCUIT OPERATION A signal from the windshield wiper switch is sent through the column-ECU inside the column switch to the front-ECU. The signal turns on the relay Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2325 inside the front-ECU to operate the wiper motor. TECHNICAL DESCRIPTION (COMMENT) The windshield wiper motor, column switch (windshield wiper and washer switch) or the front-ECU may be defective. TROUBLESHOOTING HINTS - The windshield wiper motor may be defective. - The column switch (windshield wiper and washer switch) may be defective. - The front-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the windshield wiper switches. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the windshield wiper switch is turned from "OFF" to "MIST", "INT", "LO" or "HIGH": Refer to Inspection Procedure O-16 "The windshield mist wiper switch, windshield intermittent wiper switch, windshield low-speed wiper switch, windshield high-speed wiper switch or windshield washer switch signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the windshield wiper switches. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2326 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the windshield wiper switch is turned from "OFF" to "MIST", "INT", "LO" or "HIGH": Refer to Inspection Procedure 0-16 "The windshield mist wiper switch, windshield intermittent wiper switch, windshield low-speed wiper switch, windshield high-speed wiper switch or windshield washer switch signal is not sent to the ETACS-ECU." STEP 4. Check the windshield wiper motor. 1. Disconnect the windshield wiper motor connector A-03. 2. Connect a battery to the windshield wiper motor as shown. Then check the windshield wiper motor operates normally at high and low speeds. Q: Does the windshield wiper motor operate normally? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2327 YES : Go to Step 5. NO : Replace the windshield wiper motor. Verify that the windshield wiper operates normally when the windshield wiper switch is moved to each position. STEP 5. Check windshield wiper motor connector A-03 and front-ECU connector A-11X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are windshield wiper motor connector A-03 and front-ECU connector A-11X in good condition? YES : Go to Step 6. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. Verify that the windshield wiper operates normally when the windshield wiper switch is moved to each position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2328 STEP 6. Check the wiring harness between windshield wiper motor connector A-03 (terminals 1 and 2) and front-ECU connector A-11X (terminals 27 and 28). NOTE: Also check intermediate connector C-05 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-05 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between windshield wiper motor connector A-03 (terminals 1 and 2) and front-ECU connector A-12X (terminals 27 and 28) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the windshield wiper operates normally when the windshield wiper switch is moved to each position. Inspection Procedure G-3 INSPECTION PROCEDURE G-3: Windshield Wiper and Washer: Windshield wiper does not stop at the predetermined park position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2329 Connectors Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2330 CIRCUIT OPERATION A signal from the windshield wiper switch is sent through the column-ECU inside the column switch to the front-ECU. The signal turns on the relay inside . the front-ECU to operate the wiper motor. TECHNICAL DESCRIPTION (COMMENT) The wiper motor or the front-ECU may be defective., TROUBLESHOOTING HINTS - The wiper motor may be defective. - The front-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tool: - MB991223: Test Harness Set STEP 1. Check the windshield wiper motor 1. Disconnect windshield wiper motor connector A-03. 2. Connect the windshield wiper motor connector terminal 1 to the positive battery terminal and terminal 5 to the ground as shown in the illustration (A), and operate the windshield wiper at low speed. While the windshield wiper is working, disconnect the battery at positions other than the predetermined park position to stop the windshield wiper motor. 3. When connect the windshield wiper motor connector terminal 3 to the positive battery terminal, terminal 5 to the ground and terminal 1 to terminal 4 as shown in the illustration (B), the motor should run at low speed, and then stop at the predetermined park position. Q: Does the windshield wiper motor operate normally? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2331 YES : Go to Step 2. NO : Replace the windshield wiper motor. The windshield wiper should now stop at the predetermined park position. STEP 2. Check the battery power supply circuit to the windshield wiper motor. Test at windshield wiper motor connector A-03. 1. Disconnect windshield wiper motor connector A-03 and measure the voltage available at the wiring harness side of the connector. 2. Turn the ignition switch to the "ACC" position. 3. Measure the voltage between terminal 3 and ground. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 5. NO : Go to Step 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2332 STEP 3. Check windshield wiper motor connector A-03 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is windshield wiper motor connector A-03 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The windshield wiper should now stop at the predetermined park position. STEP 4. Check the wiring harness between windshield wiper motor connector A-03 and the ignition switch (ACC). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2333 NOTE: Also check intermediate connector C-212, junction block connectors C-311 and C-312 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-212, junction block connector C-311 or C-312 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between windshield wiper motor connector A-03 and the ignition switch (ACC) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The windshield wiper should now stop at the predetermined park position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2334 STEP 5. Check windshield wiper motor connector A-03 and front-ECU connector A-11X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are windshield wiper motor connector A-03 and front-ECU connector A-11X in good condition? YES : Go to Step 6. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Refer to Harness Connector Inspection. The windshield wiper should now stop at the predetermined park position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2335 STEP 6. Check the wiring harness between windshield wiper motor connector A-03 (terminal 4) and front-ECU connector A-11X (terminal 23). NOTE: Also check intermediate connector C-05 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-05 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between windshield wiper motor connector A-03 (terminal 4) and front-ECU connector A-11X (terminal 23) in good condition? YES : Replace the front-ECU. The windshield wiper should stop at the predetermined park position. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The windshield wiper should now stop at the predetermined park position. Inspection Procedure G-4 INSPECTION PROCEDURE G-4: Windshield Wiper and Washer: Windshield intermittent wiper interval cannot be adjusted. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU calculates the intermittent wiper interval from the following input signals, and sends a signal to the front-ECU through the SWS communication line. If the signal is defective, the front-ECU will ignore the signal and set the intermittent wiper interval to four seconds. TROUBLESHOOTING HINTS - The column switch (windshield wiper and washer switch) may be defective. - The ETACS-ECU may be defective. - The front-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2336 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the windshield intermittent wiper interval adjusting knob. NOTE: If the windshield intermittent wiper interval adjusting knob is rotated from "FAST" to "SLOW when the ignition switch is at the "ON" position, the ETACS-ECU will send a signal around the medium knob position. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Check the revelent input circuit. See: Diagnosis By Symptom STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the windshield intermittent wiper interval adjusting knob. NOTE: If the windshield intermittent wiper interval adjusting knob is rotated from "FAST" to "SLOW" when the ignition switch is at the "Opposition, the ETACS-ECU will send a signal around the medium knob position. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : Check the revelent input circuit. See: Diagnosis By Symptom STEP 4. Replacement of ECU 1. Replace the front-ECU. 2. The windshield intermittent wiper interval should be changed. Q: Is it possible to adjust the windshield intermittent wiper interval? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2337 YES : No action is necessary and testing is complete. NO : Replace the ETACS-ECU. The windshield intermittent wiper interval should be changed. Inspection Procedure G-5 INSPECTION PROCEDURE G-5: Windshield Wiper and Washer: Windshield washer does not work. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2338 Connectors CIRCUIT OPERATION A signal from the windshield washer switch is sent through the column-ECU inside the column switch to the front-ECU. The signal turns on the relay inside the front-ECU to operate the windshield washer motor. TECHNICAL DESCRIPTION (COMMENT) The windshield washer motor, the column switch (windshield wiper and washer switch) or the front-ECU may be defective. TROUBLESHOOTING HINTS - The windshield washer motor may be defective. - The column switch (windshield wiper and washer switch) may be defective. - The front-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the windshield wiper. Q: Does the windshield wiper operate normally? YES : Go to Step 2 or Step 3 . NO : Refer to Inspection Procedure G-1 "Windshield wiper does not work at all." Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2339 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the windshield washer switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the windshield washer switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-16 "The windshield washer signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signal from the windshield washer switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the windshield washer switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-16 "The windshield washer signal is not sent to the ETACS-ECU ." STEP 4. Check the windshield washer motor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2340 1. Disconnect windshield washer motor connector A-33, and check at windshield washer motor connector side. 2. Fill the windshield washer tank with washer fluid. 3. When battery voltage is applied between terminals 1 and 2, washer fluid should gush out. Q: Does the windshield washer motor operate normally? YES : Go to Step 5. NO : Replace the windshield washer motor. Verify that the windshield washer works normally. STEP 5. Check the ground circuit to the windshield washer motor. Test at windshield washer motor connector A-33. 1. Disconnect windshield washer motor connector A-33 and measure the resistance available at the wiring harness side of the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2341 2. Measure the resistance value between terminal 2 and ground. - The resistance should be 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check windshield washer motor connector A-33 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is windshield washer motor connector A-33 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Verify that the windshield washer works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2342 STEP 7. Check the wiring harness between windshield washer motor connector A-33 (terminal 2) and ground. Q: Is the wiring harness between windshield washer motor connector A-33 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the windshield washer works normally. STEP 8. Check windshield washer motor connector A-33 and front-ECU connector A-11X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are windshield washer motor connector A-33 and front-ECU connector A-11X in good condition? YES : Go to Step 9. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2343 NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Verify that the windshield washer works normally. STEP 9. Check the wiring harness between windshield washer motor connector A-33 (terminal 1) and front-ECU connector A-11X (terminal 21). NOTE: Also check intermediate connector C-05 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-05 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between windshield washer motor connector A-33 (terminal 1) and front-ECU connector A-11X (terminal 21) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the windshield washer works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2344 Inspection Procedure G-6 INSPECTION PROCEDURE G-6: Windshield Wiper and Washer: Low washer fluid level warning light does not work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2345 CIRCUIT OPERATION The ETACS-ECU illuminates the low washer fluid level warning light when the washer fluid level gets lower. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU illuminates the low washer fluid level warning light according to the input signals from the following switches: - Ignition switch (IG1) - Windshield washer fluid level switch If the low washer fluid level warning light does not illuminate, the relevant input signal circuit, the combination meter (low washer fluid level warning light bulb or printed-circuit board) or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The windshield washer fluid level switch may be defective. - The combination meter (low washer fluid level warning light bulb or printed-circuit board) may be defective. - The ETACS-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check method of the input signal Q: Which is to be used, the scan tool or a voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter : Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Washer fluid level switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the washer fluid level switch float comes lower than the actual washer fluid level: Refer to Inspection Procedure O-6 "The washer fluid level switch signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2346 Check the input signals from the following switches: - Ignition switch (IG1) - Washer fluid level switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the washer fluid level switch float comes lower than the actual washer fluid level: Refer to Inspection Procedure O-6 "The washer fluid level switch signal is not sent to the ETACS-ECU. STEP 4. Check the low washer fluid level warning light circuit at the ETACS-ECU. Test at the ETACS-ECU connector C-318. 1. Disconnect the ETACS-ECU connector C-318 and measure at the harness side of the connector. 2. Turn the ignition switch to the "ON" position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2347 3. Connect terminal 70 to the ground. Q: Does the low washer fluid level warning light illuminate? YES : Replace the ETACS-ECU. Verify that the low washer fluid level warning light works normally. NO : Go to Step 5. STEP 5. Check the low washer fluid level warning light bulb. Q: Is the low washer fluid level warning light bulb in good condition? YES : Go to Step 6. NO : Replace low washer fluid level warning light bulb. The low washer fluid level warning light should now work normally. STEP 6. Check the combination meter (printed-circuit board). 1. Remove the combination meter. (Refer to Instrument Panel System.) 2. Remove the low washer fluid level warning light bulb. (Refer to Instrument Panel System.) Then measure the resistance between the bulb terminals. 3. Install the bulb to the combination meter, and then measure the resistance between connector C-101 terminal 10 and 12. The resistance reading at this time should be much the same as the resistance measured at Step (2). Q: Are the two resistance values extremely different each other? YES : Repair or replace the combination meter (printed circuit board). The low washer fluid level warning light should work normally. NO (much the same): Go to Step 7. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2348 STEP 7. Check the combination meter power supply circuit to the combination meter. Test at combination meter connector C-101. 1. Disconnect combination meter and measure the voltage available at the harness side of the connector. 2. Turn the ignition switch to the "ON" position. 3. Measure the voltage between terminal 12 and ground. - The voltage should measure approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 10. NO : Go to Step 8. STEP 8. Check the combination meter connector C-101 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is combination meter connector C-101 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic Aids Verify that the low washer fluid level warning light works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2349 STEP 9. Check the wiring harness between combination meter connector C-101 (terminal 12) and the ignition switch (IG1). NOTE: Also check junction block connectors C-308 and C-311 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-308 or C-311 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between combination meter connector C-101 (terminal 12) and the ignition switch (IG1) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the low washer fluid level warning light works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2350 STEP10. Check the combination meter connector C-101 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are combination meter connector C-101 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 11. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. Verify that the low washer fluid level warning light works normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2351 STEP 11. Check the wiring harness between combination meter connector C-101 (terminal 10) and ETACS-ECU connector C-318 (terminal 70). YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the low washer fluid level warning light works normally. Inspection Procedure G-7 INSPECTION PROCEDURE G-7: Windshield Wiper and Washer: The windshield wiper switch does not operate at all when its switch is at "INT" and "MIST" position and windshield washer switch is in the "ON" position. The windshield wiper switch operates in low Speed at "LO" and "HI." TECHNICAL DESCRIPTION (COMMENT) This system may be at fail-safe mode as the SWS communication line is defective. If the system can not receive any signal from the column switch (windshield wiper and washer switch) due to a open circuit in the SWS communication line or other reasons, the system will enter the fail-safe mode when the ignition switch is at the "ACC" position. TROUBLESHOOTING HINTS - The column switch (windshield wiper and washer switch) may be defective. - The front-ECU may be defective. - The wiring harness or connectors may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Check the DTC. Q: Does DTC set when the ignition switch is turned to the "LOCK" (OFF) position? YES : Carry out the troubleshooting by referring to Diagnostic Trouble Code Chart. NO : Replace the front-ECU. Check that the windshield wiper works normally. Inspection Procedure H-1 INSPECTION PROCEDURE H-1: Seat belt warning light: Seat belt warning light does not work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2352 CIRCUIT OPERATION The seat belt warning light illuminates when the driver turns the ignition switch to "ON" position without wearing the seat belt. TECHNICAL DESCRIPTION (COMMENT) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2353 The ETACS-ECU illuminates the seat belt warning light according to the input signals from the following switches: - Ignition switch (IG1) - Driver's seat belt switch If the seat belt warning light does not illuminate, the relevant input signal circuit, the combination meter (seat belt warning light bulb or printed-circuit board) or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The driver's side seat belt switch may be defective - The combination meter (seat belt warning light bulb or printed-circuit board) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the method of the input signal Q: Which is to be used, the scan tool or the voltmeter to check the input signal? Scan tool MB991502 : Go to Step 2. Voltmeter: Go to Step 3. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's side seat belt switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the driver's seat belt is unfastened: Refer to Inspection Procedure O-7 "The driver's seat belt switch signal is not sent to the ETACS-ECU." STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Driver's side seat belt switch Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2354 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." - The voltmeter needle does not fluctuate when the driver's seat belt is unfastened: Refer to Inspection Procedure O-7 "The driver's seat belt switch signal is not sent to the ETACS-ECU." STEP 4. Check the seat belt warning light circuit at the ETACS-ECU connector C-318. 1. Disconnect the ETACS-ECU connector C-318 and measure at the wiring harness side. 2. Turn the ignition switch to the "ON" position. 3. Connect terminal 73 to the ground. Q: Does the seat belt warning light illuminate? YES : Replace the ETACS-ECU. The seat belt warning light should work normally. NO : Go to Step 5. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2355 STEP 5. Check the seat belt warning light bulb. Q: Is the seat belt warning light bulb in good condition? YES : Go to Step 6. NO : Replace it. The seat belt warning light should work normally. STEP 6. Check the combination meter (printed-circuit board). 1. Remove the combination meter. 2. Remove the seat belt warning light bulb. Then measure the resistance between the bulb terminals. 3. Install the bulb to the combination meter, and then measure the resistance between connector C-101 terminal 12 and terminal 7. The resistance reading at this time should be much the same as the resistance measured at Step (2). Q: Are the two resistance values extremely different each other? YES : Repair or replace the combination meter (printed circuit board). The seat belt warning light should work normally. NO (much the same): Go to Step 7. STEP 7. Check the ignition switch (IG1) circuit to the combination meter. Test at combination meter connector C-101. 1. Disconnect the combination meter connector C-101 and measure the voltage available at the wiring harness side of the connector. 2. Turn the ignition switch to the "ON" position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2356 3. Measure the voltage between C-101 (terminal 12) and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 10. NO : Go to Step 8. STEP 8. Check the combination meter connector C-101 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is combination meter connector C-101 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe seat belt warning light should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2357 STEP 9. Check the wiring harness between combination meter connector C-101 (terminal 12) and ignition switch (IG1). NOTE: Also check junction block connectors C-308 and C-311 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connectors C-308 or C-311 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between combination meter connector C-101 (terminal 12) and ignition switch (IG1) in good condition? YES : No action is necessary and testing is complete. NO : Repair or replace the them. The seat belt warning light should work normally. STEP 10. Check the combination meter connector C-101 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are combination meter connector C-101 and ETACS-ECU connector C-318 in good condition? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2358 Check the combination meter connector C-102 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. YES : Go to Step 11. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe seat belt warning light should work normally. STEP 11. Check the wiring harness between combination meter connector C-101 (terminal 7) and ETACS-ECU connector C-318 (terminal 73). Q: Is the wiring harness between combination meter connector C-101 (terminal 7) and ETACS-ECU connector C-318 (terminal 73) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The seat belt warning light should work normally. Inspection Procedure I-1 INSPECTION PROCEDURE I-1: Door ajar warning light: door ajar warning light does network normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2359 CIRCUIT OPERATION If any of the doors or the trunk lid are open, ETACS-ECU illuminates door ajar warning light. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU illuminates the door ajar warning light according to the input signals from the following switches: - Driver's and passenger's door switches - Trunk lid latch switch If the door ajar warning light does not illuminate, the relevant input signal circuit, the combination meter (door ajar warning light bulb or printed-circuit board) or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The driver's or passenger's door switch may be defective - The trunk lid latch switch may be defective - The combination meter (door ajar warning light bulb or printed-circuit board) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2360 STEP 1. Verify the interior light. If the dome light switch and the rear personal light switch are moved to the "door interlock position," the interior light should illuminate should illuminate when either door or trunk lid is opened. Q: Does the interior light illuminate normally? YES : Go to Step 2. NO : Solve the problem first. Refer to Inspection Procedure M-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure M-1 STEP 2. Verify the method of the input signal Q: Which is to be used, the scan tool or the voltmeter to check the input signal? Scan tool MB991502 : Go to Step 3. Voltmeter: Go to Step 4. STEP 3. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Driver's and passenger's door switches - Trunk lid latch switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 5. NO : - Scan tool MB991502 does not sound when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 NO : Check the relevant input signal circuit. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure B-3 STEP 4. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Driver's and passenger's door switches - Trunk lid latch switch Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2361 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 5. NO : The voltmeter needle does not fluctuate when the driver's or passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 NO : - Check the relevant input signal circuit. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure B-3 STEP 5. Check the door ajar warning light circuit at the ETACS-ECU connector C-318. 1. Disconnect the ETACS-ECU connector C-318 and measure at the wiring harness side. 2. Turn the ignition switch to the "ON" position. 3. Connect terminal 53 to the ground. Q: Does the door ajar warning light illuminate? YES : Replace the ETACS-ECU. The door ajar warning light should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2362 NO : Go to Step 6. STEP 6. Check the door ajar warning light bulb. Q: Is the door ajar warning light bulb in good condition? YES : Go to Step 7. NO : Replace it. The door ajar warning light should work normally. STEP 7. Check the combination meter (printed-circuit board). 1. Remove the combination meter. 2. Remove the door ajar warning light bulb. Then measure the resistance between the bulb terminals. 3. Install the bulb to the combination meter, and then measure the resistance between connector C-102 terminal 35 and terminal 39. The resistance reading at this time should be much the same as the resistance measured at Step (2). Q: Are the two resistance values extremely different each other? YES : Repair or replace the combination meter (printed circuit board). The door ajar warning light should work normally. NO (much the same): Go to Step 8. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2363 STEP 8. Check the combination meter connector C-102 and ETACS*ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is combination meter connector C-102 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe door ajar warning light should work normally. STEP 9. Check the wiring harness between combination meter connector C-102 (terminal 35) and ETACS-ECU connector C-318 (terminal 53). Q: Are the wiring harness between combination meter connector C-102 (terminal 35) and ETACS-ECU connector C-318 (terminal 53) in good condition? YES : No action is necessary and testing is complete. NO : Repair or replace them. The door ajar warning light should work normally. Inspection Procedure J-1 INSPECTION PROCEDURE J-1: Headlight, Taillight: Taillights do not illuminate. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2364 CIRCUIT OPERATION The front-ECU illuminates the taillights if the column switch sends the taillight ON signal to the front-ECU. TECHNICAL DESCRIPTION (COMMENT) The column switch or the front-ECU may be defective. NOTE: If only one light does not illuminate, the wiring harness between the light and the front-ECU may be defective or the light bulb may be burned out. In this case, check the circuit by referring to Taillight, Position Light and License Plate Light. See: Lighting and Horns TROUBLESHOOTING HINTS - The column switch (turn-signal light and lighting switch) may be defective - The front-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the DTC. Q: Does DTC set when the ignition switch is turned to the "LOCK" (OFF) position? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2365 YES : Carry out the troubleshooting by referring to Diagnostic Trouble Code Chart. See: Trouble Code Diagnostic Charts NO : Go to Step 2 or 3 . STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the taillight switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Check "The taillight switch input signal circuit See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 3. Check the input signal (by using a voltmeter). Check the input signal from the taillight switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : Check The taillight switch input signal. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 4. Check the power supply circuit to the front-ECU. Test at front-ECU connector A-10X. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2366 1. Disconnect front-ECU connector A-1OX and measure the voltage available at the relay box side of the connector. 2. Measure the voltage between terminal 5 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the front-ECU. Check that the tail lights illuminate normally. NO : Go to Go to Step 5. STEP 5. Check the front-ECU connector A-10X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is front-ECU connector A-10X in good condition? YES : Go to Step 6. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The taillights should illuminate normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2367 STEP 6. Check the wiring harness between front-ECU connector A-1OX (terminal 5) and battery. Q: Is the wiring harness between front-ECU connector A-10X (terminal 5) and battery in good condition? YES : No action is necessary and testing is complete. Check the wiring harness between front-ECU connector A-1OX and battery. YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The taillights should illuminate normally. Inspection Procedure J-2 INSPECTION PROCEDURE J-2: Headlight, Taillight: Headlights (low-beam) do not illuminate. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2368 Connector Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2369 CIRCUIT OPERATION - If the headlight switch signal from the column switch turns on, the front-ECU makes the headlights illuminate. Whenever the headlights illuminate, the low-beam lights illuminate due to the headlight dimmer switch automatic resetting function. - If the SWS communication line is defective, the low-beam headlights will illuminate by using other signal line (headlight back-up circuit). TECHNICAL DESCRIPTION (COMMENT) The column switch or the front-ECU may be defective. NOTE: If only one of the headlights does not illuminate, the light bulb may be burned out or the wiring harness between the light and the front-ECU may be defective. In this case, check the circuit by referring to Headlight. See: Lighting and Horns/Headlamp TROUBLESHOOTING HINTS - The column switch (turn-signal light and lighting switch) may be defective - The front-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the DTC. Q: Doe the DTC set when the ignition switch is turned to the "LOCK" (OFF) position? YES : Carry out the troubleshooting by referring to Diagnostic Trouble Code Chart. See: Trouble Code Diagnostic Charts NO : Go to Step 2 or 3 . STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the headlight switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Check the headlight switch input circuit. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 3. Check the input signal (by using a voltmeter). Check the input signal from the headlight switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2370 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the lighting switch is turned from "TAIL" to "HEAD": Refer to Inspection Procedure O-14 "The headlight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 YES : Go to Step 4. STEP 4. Check the battery power supply circuit to the front-ECU. Test at front-ECU connector A-10X. 1. Disconnect front-ECU connector A-1OX and measure the voltage available at the relay box side of the connector. 2. Measure the resistance value between terminal 3 and ground, and also between terminal 4 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the front-ECU. Check that the tail lights illuminate normally. NO : Go to Go to Step 5. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2371 STEP 5. Check front-ECU connector A-10X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is front-ECU connector A-1OX in good condition? YES : Go to Step 6. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The headlights (low-beam) should illuminate normally. STEP 6. Check the wiring harness between front-ECU connector A-10X (terminal 3 and 4) and battery. Q: Is the wiring harness between front-ECU connector A-10X (terminal 3 and 4) and battery in good condition? YES : Replace the front-ECU. The headlights (low-beam) should illuminate normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The headlights (low-beam) should illuminate normally. Check the wiring harness between front-ECU connector A-10X and headlight connector (LH) A-24and headlight connector (RH) A-35. NOTE: After checking The intermediate connector C-5, check the wires. If intermediate connector C-O5 is damaged, repair or replace it. See: Diagrams/Diagnostic Aids Q: Is the wiring harness between front-ECU connector A-10X (terminal 3 and 4) and battery in good condition? YES : Replace the front-ECU. The headlights (low-beam) should illuminate normally. Inspection Procedure J-3 INSPECTION PROCEDURE J-3: Headlight, Taillight: Headlights (high-beam) do not illuminate. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2372 CIRCUIT OPERATION If the column switch sends the dimmer switch ON signal to the front-ECU, the front-ECU switches the headlights from low-beam to high-beam or vice versa. TECHNICAL DESCRIPTION (COMMENT) The column switch or the front-ECU may be defective. NOTE: If only one of the headlights does not illuminate, the light bulb may be burned out or the wiring harness between the light and the front-ECU may be defective. In this case, check the circuit by referring to Headlight. TROUBLESHOOTING HINTS. - The column switch (turn-signal light and lighting switch) may be defective - The front-ECU may be defective Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2373 - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - "MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verity the headlight (low-beam) operation. Q: Do the headlights (low-beam) illuminate normally? YES : Go to Step 2 or 3 . NO : Solve the problem first. Refer to Inspection Procedure J-2. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure J-2 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the dimmer switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the Input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the front-ECU. Check that the tail lights illuminate normally. NO : Scan tool MB991502 does not sound when the dimmer switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-14 "The dimmer switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 3. Check the input signal (by using a voltmeter). Check the input signal from the dimmer switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2374 YES : Replace the front-ECU. Check that the tail lights illuminate normally. NO : Scan tool MB991502 does not sound when the dimmer switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-14 "The dimmer switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 Inspection Procedure J-4 INSPECTION PROCEDURE J-4: Headlight, Taillight: Headlights do not illuminate when the passing switch is operated. TECHNICAL DESCRIPTION (COMMENT) If the column switch or the front-ECU is suspected to be defective. TROUBLESHOOTING HINTS - The column switch (turn-signal light and lighting switch) may be defective - The front-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the headlight (low-beam and high-beam) operation. Q: Do the headlights (low-beam and high-beam) illuminate normally? YES : Go to Step 2 or 3 . NO : Solve the problem first. See J2 See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure J-2 and J3 See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure J-3 symptom charts. STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the passing switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the front-ECU. The passing switch should work normally. NO : Scan tool MB991502 does not sound when the passing switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-14 "The passing switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 3. Check the input signal (by using a voltmeter). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2375 Check the input signal from the passing switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the front-ECU. The passing switch should work normally. NO : The voltmeter needle does not fluctuate when the passing switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-14 "The passing switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 Inspection Procedure J-5 INSPECTION PROCEDURE J-5: Headlight, Taillight: Headlight automatic shutdown function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU and front-ECU operates the headlight automatic shutdown function, based on the signals from the following switches: - Ignition switch (IG1) - Taillight switch - Headlight switch If the function does work normally, a defect on relevant input circuits, the ETACS-ECU or the front-ECU is suspected. TROUBLESHOOTING HINTS - The column switch (turn-signal light and lighting switch) may be defective - The ETACS-ECU may be defective - The front-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the DTC. Q: Does the DTC set when the ignition switch is turned to the "LOCK" (OFF) position? YES : Carry out the troubleshooting by referring to Diagnostic Trouble Code Chart. See: Trouble Code Diagnostic Charts NO : Go to Step 2 or 3 . STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches. - Ignition switch (IG1) - Driver's door switch - Taillight switch - Headlight switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2376 disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the lighting switch is turned from "OFF" to "TAIL": Refer to Inspection Procedure O-14 "The taillight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 - The voltmeter needle does not fluctuate when the lighting switch is turned from "TAIL" to "HEAD": Refer to Inspection Procedure O-14 "The headlight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches. - Ignition switch (IG1) - Driver's door switch - Taillight switch - Headlight switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the lighting switch is turned from "OFF" to "TAIL": Refer to Inspection Procedure O-14 "The Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2377 taillight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 - Scan tool MB991502 does not sound when the lighting switch is turned from "TAIL" to "HEAD": Refer to Inspection Procedure O-14 "The headlight switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 STEP 4. Replacement of ECU. 1. Replace the front-ECU. 2. The headlight automatic shutdown function should work normally. Q: Is the headlight automatic shutdown function working normally? YES : No action is necessary and testing is complete. NO : Replace the ETACS-ECU. The headlight automatic shutdown function should work normally. Inspection Procedure J-6 INSPECTION PROCEDURE J-6: Headlight, taillight: Headlight dimmer switch automatic resetting function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The headlight dimmer switch automatic resetting function is controlled by the front-ECU. If a defect appears, the front-ECU may be defective. TROUBLESHOOTING HINT The front-ECU may be defective DIAGNOSIS Replace the front-ECU. The headlight dimmer switch automatic resetting function should work normally. Inspection Procedure J-7 J-7 Headlight, taillight: Headlight dimmer switch automatic resetting function does not work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2378 CIRCUIT OPERATION When the passing switch is on or the front-ECU is illuminating the headlights (high-beam), the ETACS-ECU illuminates the high-beam indicator light. TECHNICAL DESCRIPTION (COMMENT) If the headlights (high-beam and passing) operate normally, the combination meter (high-beam indicator light bulb or printed-circuit board), the front-ECU or the ETACS-ECU is suspected to be defective. TROUBLESHOOTING HINTS - The combination meter (high-beam indicator light bulb or printed-circuit board) may be defective - The front-ECU may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tool: - MB991223: Test Harness Set STEP 1. Verify the headlights (high-beam and passing) operation. Q: Do the headlights (high-beam and passing) illuminate normally? YES : Go to Step 2. NO : Solve the problem first. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure J-6 STEP 2. Check the high-beam indicator light circuit at the ETACS-ECU connector C-318. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2379 1. Disconnect the ETACS-ECU connector C-318 and measure at the wiring harness side. 2. Connect terminal 72 to the ground. Q: Does the high-beam indicator light illuminate? YES : Go to Step 10. NO : Go to Step 3. STEP 3. Check the high-beam indicator light bulb. Q: Is the high-beam indicator light bulb in good condition? YES : Go to Step 4. NO : Replace it. The high-beam indicator light should work normally. STEP 4. Check the combination meter (printed-circuit board). 1. Remove the combination meter. 2. Remove the high-beam indicator light bulb. Then measure the resistance between the bulb terminals. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2380 3. Install the bulb to the combination meter, and then measure the resistance between connector C-101 terminal 4 and 5. The resistance reading at this time should be much the same as the resistance measured at Step (2). Q: Are the two resistance values extremely different each other? YES : Repair or replace the combination meter (printed circuit board). The high-beam indicator light should work normally. NO (much the same): Go to Step 5. STEP 5. Check the battery power supply circuit to the combination meter. Test at combination meter connector C-101. 1. Disconnect the combination meter connector C-101 and measure the voltage available at the wiring harness side of the connector. 2. Measure the voltage between terminal 4 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check the combination meter connector C-101 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2381 Q: Is combination meter connection C-101 in good condition? YES : go to step 7. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The high-beam indicator light should work normally. STEP 7. Check the wiring harness between combination meter connector C-101 (terminal 4) and battery. NOTE: Also check junction block connector C-308 and c-313 and intermediate connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-308 or C-313 or intermediate connector C-209 is damaged, repair or replace the damaged component(s). Q: Are the wiring harness between combination meter connector C-101 and battery in good condition? YES : No action is necessary and testing is complete. NO : Repair or replace them. The high-beam indicator light should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2382 STEP 8. Check the combination meter connector C-101 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are combination meter connector C-101 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The high-beam indicator light should work normally. STEP 9. Check the wiring harness between combination meter connector C-101 (terminal 5) and ETACS-ECU connector C-318 (terminal 72). Q: Is the wiring harness between combination meter connector C-101 (terminal 5) and ETACS-ECU connector C-318 (terminal 72) in good condition? YES : No action is necessary and testing is complete. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2383 NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The high-beam indicator light should work normally. STEP 10. Replacement of ECU. 1. Replace the ETACS-ECU. 2. The high-beam indicator light should work normally. Q: Is the high-beam indicator light working normally? YES : No action is necessary and testing is complete. NO : Replace the front-ECU. The high-beam indicator light should work normally. Inspection Procedure J-8 INSPECTION PROCEDURE J-8: Headlight, tail light: headlights do not illuminate when the lighting switch is at 'tail' and 'passing' position, but illuminate at low-beam when the switch is at 'head' position, at this position, the headlights cannot be changed by operating the dimmer switch. TECHNICAL DESCRIPTION (COMMENT) If the headlights illuminate at low-beam regardless of the lighting switch positions, the headlight operation is in fail-safe mode. TROUBLESHOOTING HINTS - The column switch may be defective - The front-ECU may be defective - The ETACS-ECU may be defective - Damaged wiring harness and connectors Check the DTC. Q: Does DTC set when the ignition switch is turned to the 'LOCK (OFF) position? YES : Carry out the troubleshooting by referring to Diagnostic Trouble Code Chart. NO : Replace the front-ECU. Check that the headlights and the tail lights illuminate normally. Inspection Procedure K-1 INSPECTION PROCEDURE K-1: Flasher timer: Turn-signal lights does not flash when the turn-signal light switch is turned on. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2384 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2385 Connectors CIRCUIT OPERATION - The turn-signal light switch sends a signal through the column-ECU (incorporated in the column switch) to the ETACS-ECU. If the column-ECU sends a turn-signal light switch 'ON' signal to the ETACS-ECU, the ETACS-ECU turns on the flasher timer (incorporated in the ETACS-ECU), thus causing the turn-signal lights to flash. - The ETACS-ECU operates the turn-signal lights according to the following signals: - Ignition switch (IG1) - Turn-signal light switch TECHNICAL DESCRIPTION (COMMENT) Is the turn-signal lights do not flash normally, the input circuits from the switches described in 'CIRCUIT OPERATION' or the ETACS-ECU may be defective. If the hazard warning lights do not flash, the power supply line to the ETACS-ECU (dedicated to the turn-signal lights) may be defective. TROUBLESHOOTING HINTS - The column switch (turn-signal light and lighting switch) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the hazard warning light operation. Q: Do the hazard warning lights work normally? YES : Go to Step 7 or 8 . NO : Go to Step 2. STEP 2. Verify the turn-signal light state operation. Q: Does any turn-signal lights flash? YES (only one side illuminates): Go to Step 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2386 NO (no lights flash at all): Go to Step 4. STEP 3. Check the ETACS-ECU connector C-319 and junction block connectors C-301, C-308 and C-312 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are ETACS-ECU connector C-319 and junction block connectors C-301, C-308 and C-312 in good condition? YES : Replace the ETACS-ECU. The turn-signal lights should flash normally. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The turn-signal lights should flash normally. STEP 4. Check the power supply circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect the ETACS-ECU connector C-319 and measure at the junction block side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2387 2. Measure the voltage between terminal 11 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the ETACS-ECU. The turn-signal lights should flash normally. NO : Go to Step 5. STEP 5. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The turn-signal lights should flash normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2388 STEP 6. Check the wiring harness between ETACS-ECU connector C-319 (terminal 11) and battery. NOTE: Also check junction block connector C-312 and intermediate connector C-209, check the wires. If junction block connector C-312 and intermediate connector C-209 are damaged, repair or replace them. Refer to Harness Connector Inspection. Q: Are the wiring harness between ETACS-ECU connector C-319 (terminal 11) and battery in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The turn-signal lights should flash normally. STEP 7. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches. - Ignition switch (IG1) - Turn-signal light switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the 'LOCK' (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The turn-signal lights should flash normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2389 NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the turn-signal light switch is turned from "OFF" to "left turn" and "right turn": Refer to Inspection Procedure O-14 "The turn signal light switch signal is not sent to the ETACS-ECU ." See: Diagrams/Diagnostic Aids STEP 8. Check the input signal (by using a voltmeter). Check the input signals from the following switches. - Ignition switch (IG1) - Turn-signal light switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The turn-signal lights should flash normally. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the turn-signal light switch is turned from "OFF" to "left turn" and "right turn": Refer to Inspection Procedure O-14 "The turn signal light switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-14 Inspection Procedure K-2 INSPECTION PROCEDURE K-2: Flasher Timer: Hazard warning lights does not flash when the hazard warning light switch is turned on. TURN-SIGNAL LIGHT DRIVE CIRCUIT - Refer to Inspection Procedure K-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure K-1 CIRCUIT OPERATION If the ETACS-ECU receives a signal from the hazard warning light switch, the flasher timer circuit (which is incorporated in the ETACS-ECU) makes the turn-signal lights flash. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU makes the turn-signal lights flash, based on the input signals from the hazard warning light switch. If the turn-signal lights do not flash normally, the hazard warning light switch input circuit or the ETACS-ECU may be defective. If the turn-signal lights do not flash, a defect in the ETACS-ECU power supply line specific to the turn-signal lights is suspected. NOTE: If only one of the turn-signal lights does not flash, the light bulb may be burned out or the wiring harness between the ETACS-ECU and the light may be defective. In this case, check the circuit by referring to Turn-signal Light and Hazard Warning Light. TROUBLESHOOTING HINTS - The hazard warning light switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2390 - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the turn-signal light operation. Q: Do the turn-signal lights work normally? YES : Go to Step 2 or 3 . NO : Solve the problem first. Refer to Inspection Procedure K-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure K-1 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the hazard warning light switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The hazard warning lights should flash normally. NO : Scan tool MB991502 does not sound when the hazard warning light switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-4 "The hazard switch signal is not sent to the ETACS-ECU."v See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-4 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the hazard warning light switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The hazard warning lights should flash normally. NO : The voltmeter needle does not fluctuate when the hazard warning light switch is turned from "OFF" to "ON": Refer to Inspection Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2391 Procedure O-4 "The hazard switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-4 Inspection Procedure L-1 INSPECTION PROCEDURE L-1: Fog Light: Fog lights do not illuminate when the fog light switch is turned on. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2392 Connectors CIRCUIT OPERATION -5Ghen the fog light switch is turned on while the front-ECU is illuminating the taillights or headlights (low-beam), the ETACS-ECU sends a 'light on' signal to the front-ECU, causing the front-ECU to illuminate the fog lights. TECHNICAL DESCRIPTION (COMMENT) If the taillights and headlights illuminate normally, the fog light relay, the fog light switch, the front-ECU or the ETACS-ECU may be defective. NOTE: If only one of the fog lights or the fog light indicator light does not illuminate, the relevant bulb may be burned out or the wiring harness between the defective light and the fog light relay may be defective. In this case, check the relevant circuit by referring to Fog Light. See: Lighting and Horns/Fog/Driving Lamp/Diagrams TROUBLESHOOTING HINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2393 - The fog light switch may be defective - The front-ECU may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB001223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the taillights and headlight operation. Q: Do the taillights and headlights illuminate normally? YES : Go to Step 2 or 3 . NO : Solve the problem first. See: Diagnosis By Symptom STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the fog light switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the 'LOCK' (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the fog light switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-5 "The fog light switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-5 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the fog light switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2394 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : The voltmeter needle does not fluctuate when the fog light switch is turned from "OFF" to "ON": Refer to Inspection Procedure O-5 "The fog light switch signal is not sent to the ETACS-ECU. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-5 STEP 4. Check the fog light relay. Q: Is the fog light relay in good condition? YES : Go to Step 5. NO : Replace the fog light relay. The fog lights should illuminate normally. STEP 5. Check the power supply circuit to the fog light relay. Test at fog light relay connector A-04X. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2395 1. Disconnect the fog light relay connector A-04X and measure the voltage available at the relay box side of the connector. 2. Measure the resistance value between terminal 1 and ground, and also between terminal 2 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 8. NO : Go to Step 6. STEP 6. Check the fog light relay connector A-04X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is fog light relay connector A-04X in good condition? YES : Go to Step 7. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe fog lights should illuminate normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2396 STEP 7. Check the wiring harness between fog light relay connector A-04X (terminal 1 and 2) and battery. Q: Is the wiring harness between fog light relay connector A-04X (terminal 1 and 2) and battery in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The fog lights should illuminate normally. STEP 8. Check the fog light relay connector A-04X and front-ECU connector A-10X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are fog light relay connector A-04X and front-ECU connector A-10X in good condition? YES : Go to Step 9. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe fog lights should illuminate normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2397 STEP 9. Check the wiring harness between fog light relay connector A-04X (terminal 3) and front-ECU connector A-10X (terminal 1). Q: Is the wiring harness between fog light relay connector A-04X (terminal 3) and front-ECU connector A-10X (terminal 1) in good condition? YES : Go to Step 10. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The fog lights should illuminate normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2398 STEP 10. Check the fog light connectors A-27 and A-31 and combination meter connector C-101 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are fog light connectors A-27 and A-31 and combination meter connector C-101 in good condition? YES : Go to Step 11. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe fog lights should illuminate normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2399 STEP 11. Check the wiring harness between fog light relay connector A-04X (terminal 4) and fog light connectors A-27 (terminal 2) and A-31 (terminal 2) and combination meter connector C-101 (terminal 2). NOTE: Also check intermediate connectors C-05 and C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connectors C-05 or C-209 are damaged, repair or replace the damaged components) Refer to Harness Connector Inspection. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2400 Q: Are the wiring harness between fog light relay connector A-04X (terminal 4) and fog light connectors A-27 (terminal 2) and A-31 (terminal 2) and combination meter connector C-103 (terminal 2) in good condition? YES : Go to Step 12. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2401 NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The fog lights should illuminate normally. STEP 12. Replacement of ECU 1. Replace the front-ECU. 2. The fog lights should illuminate normally. Q: Do the fog lights illuminate normally? YES : No action is necessary and testing is complete. NO : Replace the ETACS-ECU. The fog light should illuminate normally. Inspection Procedure L-2 INSPECTION PROCEDURE L-2: Fog light; Fog lights do not go out when the headlights (low-beam) are turned off while the fog lights are on. TECHNICAL DESCRIPTION (COMMENT) If the malfunction above occurs, the front-ECU may be defective. TROUBLESHOOTING HINT The front-ECU may be defective DIAGNOSIS Replace the front-ECU. The fog lights should go out when the headlights (low-beam) are turned off while the fog lights are on. Inspection Procedure M-1 INSPECTION PROCEDURE M-1: Interior light: Interior light does not work normally. CIRCUIT OPERATION Interior lights (dome light and rear personal lights and foot lights and trunk light) are turned on and off by ETACS-ECU. Interior lights are controlled by ETACS-ECU, only when switch position is set to the position 'door controlled operation position'. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2402 TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the interior light automatic shutoff function according to the following switch signals. - Ignition switch (IG1) - Key reminder switch - Driver's or passenger's door switches - Driver's door lock actuator switch - Trunk lid latch switch - Dedicated fuse No. 17 loaded signal If the interior light does not illuminate normally, the relevant input signal circuit or the ETACS-ECU may be defective. NOTE: If only one the interior lights does not illuminate, the relevant bulb may be burned out or the wiring harness between the defective light and the ETACS-ECU may be defective. In this case, check the relevant circuit by referring to Interior Lights. TROUBLESHOOTING HINTS - The key reminder switch may be defective - The driver's or passenger's door switches be defective - The driver's door lock actuator switch may be defective - The trunk lid latch switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the ETACS-ECU power supply circuit. Check that the hazard warning light illuminate when the ignition switch is in the 'LOCK' (OFF) position. Q: Does the hazard warning light illuminate? YES : Go to Step 2 or 3 . NO : Check the ETACS-ECU battery circuit. Refer to Inspection Procedure P-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure P-1 STEP 2. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Key reminder switch - Driver's and passenger's door switch - Driver's door lock actuator switch - Trunk lid latch switch - Interior light loaded signal CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the 'LOCK' (OFF) position before connecting or disconnecting scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2403 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 4. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - Scan tool MB991502 does not sound when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the driver's door is unlocked by using the inside lock knob: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." - Scan tool MB991502 does not sound when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - Scan tool MB991502 does not sound when approximately 30 minutes elapses while the drivers or passenger door is open: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 STEP 3. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Key reminder switch - Driver's and passenger's door switch - Driver's door lock actuator switch - Trunk lid latch switch - Interior light loaded signal 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 4. NO : - The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - The voltmeter needle does not fluctuate when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the driver's door is unlocked by using the inside lock knob: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-10 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure 0-12 "The trunk lid latch switch signal Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2404 is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - The voltmeter needle does not fluctuate when approximately 30 minutes elapses while the driver's or passenger's door is open: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 STEP 4. Check the ETACS-ECU connectors C-318 and C-319 and junction block connectors C-301 and C-302 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are ETACS-ECU connectors C-318 and C-319 and junction block connectors C-301 and C-302 in good condition? YES : Go to Step 5. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic Aids The interior lights should illuminate normally. STEP 5. Confirm which one of the interior lights does not illuminate. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2405 If the dome light is integrated with the inside rear view mirror, the mirror assembly built-in circuit makes the dome light illuminate. Q: Is the dome light integrated in the inside rear view mirror? YES: Check the power supply line to the inside rear view mirror (by means of the indicator light). Refer to Inside rear view mirror diagnosis?. NO: Replace the ETACS-ECU. Check that the interior light dim normally. STEP 5. Check the harness wire betqween ETACS-ECU connectore C-319 and junction block connector C-301 and C-302 in good condition? YES: replace the ETACS-ECU. The interior lights should illuminate normally. NO: Repair it. The interior lights should illuminate normally. Inspection Procedure M-2 INSPECTION PROCEDURE M-2: Interior light: Interior light dimming function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the interior light dimming function according to the following switch signals. - Ignition switch (IG1) - Key reminder switch - Driver's or passenger's door switches - Driver's door lock actuator switch If the interior light does not dim normally, the relevant input signal circuit or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The key reminder switch may be defective - The driver's or passenger's door switches may be defective - The driver's door lock actuator switch may be defective Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2406 - The ETACS-ECU may be defective The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the interior light. If the dome light switch and the rear personal light switch are moved to the 'door interlock position,' the interior light should illuminate when either door is opened. Q: Does the interior light illuminate normally? YES : Go to Step 2. NO : Solve the problem first. Refer to Inspection Procedure M-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure M-1 STEP 2. Verify the ETACS-ECU power supply circuit. Check that the hazard warning light illuminate when the ignition switch is in the 'LOCK' (OFF) position. Q: Does the hazard warning light illuminate? YES : Go to Step 3 or 4 . NO : Check the ETACS-ECU battery circuit. Refer to Inspection Procedure P-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure P-1 STEP 3. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (IG1) - Key reminder switch - Driver's and passenger's door switches - Driver's door lock actuator switch CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the 'LOCK' (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 5. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2407 reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - Scan tool MB991502 does not sound when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the driver's door is unlocked: Refer to Inspection Procedure 0-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-10 STEP 4. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (IG1) - Key reminder switch - Driver's and passenger's door switch - Driver's door lock actuator switch 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 5. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - The voltmeter needle does not fluctuate when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the driver's door is unlocked: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-10 STEP 5. Confirm which one of the interior lights does not fade out. If the dome light is integrated with the inside rear view mirror, the mirror assembly built-in circuit makes the dome light fade out. Q: Is the dome light integrated in the inside rear view mirror? YES : Go to Step 6. NO : Replace the ETACS-ECU. Check that the interior light dim normally. STEP 6. Check by replacing the inside rear view mirror. 1. Replace the inside rear view mirror. 2. Check if the dome light fades out. Q: Does the dome light fade out? YES : No action is necessary and testing is complete. NO : Replace the ETACS-ECU. Check that the interior light dim normally. Inspection Procedure M-3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2408 INSPECTION PROCEDURE M-3: Interior light: Interior light automatic shutoff function does not work normally. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the interior light automatic shutoff function according to the following switch signals. - Ignition switch (ACC) - Ignition switch (IG1) - Driver's or passenger's door switches - Trunk lid latch switch - Interior light loaded signal If the interior light automatic shutoff function does not work normally, the relevant input signal circuit or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The key reminder switch may be defective - The driver's or passenger's door switches may be defective - The trunk lid latch switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the interior light. If the dome light switch and the rear personal light switch are moved to the 'door interlock position,' the interior light should illuminate when either door or trunk lid is opened. Q: Does the interior light illuminate normally? YES : Go to Step 2. NO : Solve the problem first. Refer to Inspection Procedure M-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure M-1 STEP 2. Verify the ETACS-ECU power supply circuit. Check that the hazard warning light illuminate when the ignition switch is in the 'LOCK' (OFF) position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2409 Q: Does the hazard warning light illuminate? YES : Go to Step 3 or 4 . NO : Check the ETACS-ECU battery circuit. Refer to Inspection Procedure P-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure P-1 STEP 3. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition switch (ACC) - Ignition switch (IG1) - Driver's and passenger's door switches - Trunk lid latch switch - Interior light loaded signal CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the 'LOCK' (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Go to Step 5. NO : Scan tool MB991502 does not sound when the ignition switch is turned from "OFF (LOCK)" to "ACC": Refer to Inspection Procedure O-1 "The ignition switch (ACC) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-1 - Scan tool MB991502 does not sound when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - Scan tool MB991502 does not sound when each of the driver's and passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - Scan tool MB991502 does not sound when approximately 30 minutes elapses while the drivers or passenger door is open: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 STEP 4. Check the input signal (by using a voltmeter). Check the input signals from the following switches: - Ignition switch (ACC) - Ignition switch (IG1) - Driver's and passenger's door switch - Trunk lid latch switch - Interior light loaded signal Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2410 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Go to Step 5. NO : The voltmeter needle does not fluctuate when the ignition switch is turned from "OFF (LOCK)" to "ACC": Refer to Inspection Procedure O-1 "The ignition switch (ACC) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-1 - The voltmeter needle does not fluctuate when the ignition switch is turned from "ACC" to "ON": Refer to Inspection Procedure O-2 "The ignition switch (IG1) signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-2 - The voltmeter needle does not fluctuate when each of the driver's and passenger's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - The voltmeter needle does not fluctuate when approximately 30 minutes elapses while the driver's or passenger's door is open: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 STEP 5. Confirm which interior light is the automatic shutoff function disabled on. If the dome light is integrated in the inside rear view mirror, the mirror assembly built-in circuit turns off the dome light automatically: Q: Is the dome light integrated in the inside rear view mirror? YES : Go to Step 6. NO : Replace the ETACS-ECU. Check that the interior light automatic shutdown function works normally. STEP 6. Check by replacing the inside rear view mirror. 1. Replace the inside rear view mirror. 2. Check that the interior light automatic shutoff function for the dome light works normally. Q: Does the interior light automatic shutoff function for the dome light work? YES : No action is necessary and testing is complete. NO : Replace the ETACS-ECU. Check that the interior light automatic shutdown function works normally. Inspection Procedure N-1 INSPECTION PROCEDURE N-1: Theft-alarm system: Theft-alarm system is not armed (security indicator light does not illuminate). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2411 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2412 Connectors CIRCUIT OPERATION The theft-alarm system will be armed after the doors are locked and then the security indicator light has illuminated for approximately 18 seconds. TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU arms the theft-alarm system according to the input signals from the following switches: - Ignition key reminder switch - Driver's and passenger's door switch - Driver's and passenger's door key cylinder switch - Driver's and front passenger's door lock actuator switch - Trunk lid latch switch - Transmitter If the theft-alarm system is armed normally, the relevant input signal circuit(s), the theft-alarm indicator light or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The combination meter (security indicator light bulb or printed-circuit board) may be defective - The driver's or passenger's door switch may be defective - The driver's or passenger's door lock key cylinder switch may be defective - The driver's or passenger's door lock actuator switch may be defective - The trunk lid latch switch may be defective - The transmitter may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness. STEP 1. Check the ETACS-ECU power supply circuit. Check that the hazard warning light illuminate when the ignition switch is in the 'LOCK' (OFF) position. Q: Does the hazard warning light illuminate? YES : Go to Step 2 . Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2413 NO : Check the ETACS-ECU battery circuit. Refer to Inspection Procedure P-1. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure P-1 STEP 2. Check the security indicator circuit at the ETACS-ECU connector C-318. 1. Disconnect the ETACS-ECU connector C-318 and measure at the wiring harness side. 2. Connect terminal 74 to the ground. Q: Does the security indicator light illuminate? YES : Go to Step 10 or 11 . NO : Go to Step 3 . STEP 3. Check the security indicator light bulb. Q: Is the security indicator light bulb in good condition? YES : Go to Step 4 . NO : Replace it. The security indicator light should illuminate, and the theft-alarm system should be armed normally. STEP 4. Check the combination meter (printed-circuit board). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2414 1. Remove the combination meter. 2. Remove the seat belt warning light bulb. The measure the resistance between the bulb terminals. 3. Install the bulb to the combination meter, and then measure the resistance between connector C-101 terminal 1 and 47. The resistance reading at this time should be much the same as the resistance measured at Step (2). Q: Are the two resistance values extremely different each other? YES : Repair or replace the combination meter (printed-circuit board). The security indicator light should illuminate, and the theft-alarm system should be armed normally. NO : Go to Step 5. STEP 5.Check the battery power supply circuit to the combination meter. Test at combination meter connector C-101. 1. Disconnect the combination meter connector C-101 and measure the voltage available at the wiring harness side of the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2415 2. Measure the voltage between terminal 32 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 8 . NO : Go to Step 6. STEP 6. Check the combination meter connector C-101 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is combination meter connector C-101 in good condition. YES : Go to Step 7. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe security indicator light should illuminate, and theft-alarm system should be armed normally. STEP 7. Check the wiring harness between combination meter connector C-101 and battery. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2416 NOTE: Also check joint connector C-141 and intermediate connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If joint connector C-141 and intermediate connector C-209 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-17 Q: Are the wiring harness between combination meter connector C-101 and battery in good condition? YES : No action is necessary and testing is complete. NO : Repair or replace them. The security indicator light should illuminate, and the theft-alarm system should be armed normally. STEP 8. Check the combination meter connector C-102 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are combination meter connector C-102 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The security indicator light should illuminate, and the theft-alarm system should be armed normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2417 STEP 9. Check the wiring harness between combination meter connector C-102 and ETACS-ECU connector C-318. Q: Is the wiring harness between combination meter connector C-102 (terminal 47) and ETACS-ECU connector C-318 (terminal 74) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The security indicator light should illuminate, and the theft-alarm system should be armed normally. STEP 10. Check the input signal (by using scan tool MB991502). Check the input signals from the following switches: - Ignition key reminder switch - Driver's door switch - Driver's and passenger's door key cylinder switch - Driver's and front passenger's door lock actuator switch - Trunk lid latch switch - Transmitter CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the 'LOCK' (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2418 Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The security indicator light should illuminate, and the theft-alarm system should be armed normally. NO : Scan tool MB991502 does not sound when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - Scan tool MB991502 does not sound when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - Scan tool MB991502 does not sound when each of the driver's and passenger's door is unlocked by using the ignition key: Refer to Inspection Procedure O-9 "The driver's and passenger's door key cylinder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-9 - Scan tool MB991502 does not sound when each of the driver's and passenger's door is unlocked by using the inside lock knob: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-10 - Scan tool MB991502 does not sound when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - Scan tool MB991502 does not sound when the doors are locked and unlocked by using the transmitter: Refer to Inspection Procedure O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-17 STEP 11. Check the input signal (by using scan tool voltmeter). Check the input signals from the following switches: - Ignition key reminder switch - Driver's door switch - Driver's and passenger's door key cylinder switch - Driver's and front passenger's door lock actuator switch - Trunk lid latch switch - Transmitter 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator deflects once when the input signal enters. Q: Does the voltmeter indicator deflect? YES : Replace the ETACS-ECU. The security indicator light should illuminate, and the theft-alarm system should be armed normally. NO : The voltmeter needle does not fluctuate when the ignition key is inserted and then removed: Refer to Inspection Procedure O-3 "The key reminder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-3 - The voltmeter needle does not fluctuate when the driver's door is opened: Refer to Inspection Procedure O-8 "The driver's or passenger's door switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-8 - The voltmeter needle does not fluctuate when each of the driver's and passenger's door is unlocked by using the ignition key: Refer to Inspection Procedure O-9 "The driver's and passenger's door key cylinder switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-9 - The voltmeter needle does not fluctuate when each of the driver's and passenger's door is unlocked by using the inside lock knob: Refer to Inspection Procedure O-10 "The driver's or passenger's door lock actuator switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-10 - The voltmeter needle does not fluctuate when the trunk lid is opened: Refer to Inspection Procedure O-12 "The trunk lid latch switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-12 - The voltmeter needle does not fluctuate when the doors are locked and unlocked by using the transmitter: Refer to Inspection Procedure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2419 O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-17 Inspection Procedure N-2 INSPECTION PROCEDURE N-2: Theft-alarm system: Horn does not sound when the theft-alarm is triggered. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2420 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2421 CIRCUIT OPERATION The ETACS-ECU will sound the theft-alarm horn and horn if the theft-alarm system or the keyless entry system answerback is triggered. TECHNICAL DESCRIPTION (COMMENT) The theft-alarm horn is shared by the keyless entry system. If the theft-alarm horn sounds normally through the keyless entry system answerback, the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The theft-alarm horn may be defective - The theft-alarm horn relay may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tool: - MB991223: Test Harness Set STEP 1. Verify the keyless entry system horn answerback. Activate the keyless entry system horn answerback. (Refer to Keyless Entry System - On-vehicle Service -Enabling/disabling the Answerback Function.) Q: Does the horn answerback function work? YES : Replace the ETACS-ECU. The horn should sound when the theft-alarm system is triggered. NO : Go to Step 2. STEP 2. Check the theft-alarm horn. Connect the battery as shown and check that the theft-alarm horn sounds. Q: Is the theft-alarm horn in good condition? YES : Go to Step 3. NO : Replace it. The horn should sound when the theft-alarm system is triggered. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2422 STEP 3. Check the theft-alarm horn relay. Q: Is the theft-alarm horn relay in good condition? YES : Go to Step 4. NO : Replace it. The horn should sound when the theft-alarm system is triggered. STEP 4. Check the theft-alarm horn relay power supply circuit at the theft-alarm horn relay connector A-06X. 1. Disconnect the theft-alarm horn relay connector A-06X and measure at the relay box side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2423 2. Measure the voltages between terminals 1, 2 and ground. - The voltage should equal approximately 12 volts(battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 7. NO : Go to Step 5. STEP 5. Check the theft-alarm horn relay connector A-06X for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is theft-alarm horn relay connector A-06X in good condition? YES : Go to Step 6. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe theft-alarm horn should sound when the theft-alarm system is triggered. STEP 6. Check the wiring harness between theft-alarm horn relay connector A-06X (terminal 1 and 2) and fusible link (4). Q: Are the wiring harness between theft-alarm horn relay connector A-06X (terminal land 2) and fusible link (4) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2424 connector. Repair the wiring harness as necessary. The horn should sound when the theft-alarm system is triggered. STEP 7. Check the theft-alarm horn relay connector A-06X and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are theft-alarm horn relay connector A-06X and ETACS-ECU connector C-317 in good condition? YES : Go to Step 8. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe horn should sound when the theft-alarm system is triggered. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2425 STEP 8. Check the wiring harness between theft-alarm horn relay connector A-06X (terminal 3) and ETACS-ECU connector C-317 (terminal 40). NOTE: Also check intermediate connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-209 is damaged, repair or replace it. Refer to Harness Connector Inspection. Q: Are the wiring harness between theft-alarm horn relay connector A-06X (terminal 3) and ETACS-ECU connector C-317 (terminal 40)in good condition? YES : Go to Step 9. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The horn should sound when the theft-alarm system is triggered. 2003-2004 Models STEP 8. Check the wiring harness between theft-alarm horn relay connector A-06X and ETACS-ECU connector C-317. NOTE: Also check intermediate connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-209 is damaged, repair or replace it. Refer to Harness Connector Inspection. Q: Are the wiring harness between theft-alarm horn relay connector A-06X (terminal 3) and ETACS-ECU connector C-317 (terminal 40) in good condition? YES : Go to Step 9. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The horn should sound when the theft-alarm system is triggered. 2002 Model Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2426 STEP 9. Check the theft-alarm horn relay connector A-06X and theft-alarm horn connector A-25 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are theft-alarm horn relay connector A-06X and theft-alarm horn connector A-25 in good condition? YES : Go to Step 10. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe horn should sound when the theft-alarm system is triggered. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2427 STEP 10. Check the wiring harness between theft-alarm horn relay connector A-06X (terminal 4) and theft-alarm horn connector A-25 (terminal 1). Q: Is the wiring harness between horn relay connector A-06X (terminal 4) and theft-alarm horn connector A-25 (terminal 1) in good condition? YES: Go to Step 11. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged , terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The theft-alarm horn should sound when the theft-alarm system is triggered. 2003-2004 Models Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2428 STEP 10. Check the wiring harness between theft-alarm horn relay connector A-06X and theft-alarm horn connector A-25. Q: Is the wiring harness between horn relay connector A-06X and theft-alarm horn connector A-25 in good condition? YES: Go to Step 11. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged , terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The theft-alarm horn should sound when the theft-alarm system is triggered. 2002Models STEP 11. Check that the theft-alarm horn is installed properly. NOTE: The theft-alarm horn is grounded to the body through the installation bolts. Q: Is the theft-alarm horn installation in good condition? YES : Replace the ETACS-ECU. The horn should sound when the theft-alarm system is triggered. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The horn should sound when the theft-alarm system is triggered. Inspection Procedure N-3 INSPECTION PROCEDURE N-3: Theft-alarm system: Headlights (high-beam) do not flash when the theft-alarm system is triggered. TECHNICAL DESCRIPTION (COMMENT) If the headlights (high-beam) work normally, the front-ECU or the ETACS-ECU may be defective. TROUBLESHOOTING HINTS - The front-ECU may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS STEP 1. Verify the headlight (high-beam) operation. Q: Do the headlights (high-beam) illuminate normally? YES : Go to Step 2. NO : Solve the problem first. See: Diagnosis By Symptom STEP 2. Replacement of ECU 1. Replace the ETACS-ECU. 2. The headlights (high-beam) should flash when the theft alarm system is triggered. Q: Do the headlights (high-beam) flash normally by the theft-alarm system? YES : No action is necessary and testing is complete. NO : Replace the front-ECU. The headlights (high-beam) should flash when the theft-alarm system is triggered. Inspection Procedure N-4 INSPECTION PROCEDURE N4: Theft-alarm system: Panic alarm function does not work. TECHNICAL DESCRIPTION (COMMENT) If the keyless entry system is normal, the ETACS- ECU is defective. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2429 DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the keyless entry system. Q: Does the keyless entry system work normally? YES : Go to Step 2 or 3. NO : Solve the problem first. See: Diagnosis By Symptom STEP 2. Check the input signal (by using scan tool MB991502). Check the input signal from the transmitter "PANIC" switch. CAUTION : To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. 2. Check that the tone alarm of scan tool MB991502 sounds when the input signal enters. Q: Does the tone alarm of scan tool MB991502 sound when the input signal enters? YES : Replace the ETACS-ECU. The panic alarm should work normally. NO : Scan tool MB991502 does not sound when the transmitter panic switch is depressed: Refer to Inspection Procedure O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-17 STEP 3. Check the input signal (by using scan tool MB991502). Check the input signals from the transmitter "PANIC" switch. 1. Use special tool MB991529 to connect a voltmeter between ground terminal 4 or 5 and ETACS-ECU terminal 9 of the data link connector. 2. Check that the voltmeter indicator defects once when the input signal enters. Q: Does the voltmeter indicator deflect? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2430 YES : Replace the ETACS-ECU. The panic alarm should work normally. NO : The voltmeter needle does not fluctuate when the transmitter panic switch is depressed: Refer to Inspection Procedure O-17 "The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU." See: Diagnosis By Symptom/Symptom Procedures/Inspection Procedure O-17 Inspection Procedure O-1 INSPECTION PROCEDURE 0-1: The ignition switch (ACC) signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2431 Connector CIRCUIT OPERATION The ETACS-ECU operates various functions according to the input signal from the ignition switch (ACC). TECHNICAL DESCRIPTION (COMMENT) The ignition switch (ACC) input signal is used to operate the following devices or functions: - Windshield wiper and washer - Interior light automatic shutoff function If the signal fails, these devices or functions will not work normally. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the ignition switch (ACC) circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect the ETACS-ECU connector C-319 and measure the voltage available at the junction block side of the connector. 2. Turn the ignition switch to the 'ACC' position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2432 3. Measure the voltage between terminal 4 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the ETACS-ECU. The ignition switch (ACC) input signal should be able to be checked and the devices or functions, which are described in the 'Technical Description (comment),' should work normally. NO : Go to Step 2. STEP 2. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic Aids The ignition switch (ACC) input signal should be able to be checked and the devices or functions, which are described in the Technical Description (comment), should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2433 STEP 3. Check the wiring harness between ETACS-ECU connector C-319 (terminal 4) and ignition switch (ACC). NOTE: Also check junction block connector C-312 and intermediated connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-312 or intermediated connector C-209 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. See: Diagrams/Diagnostic Aids Q: Are the wiring harness between ETACS-ECU connector C-319 (terminal 4and ignition switch (ACC) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The ignition switch (ACC) input signal should be able to be checked and the devices or functions, which are described in the technical description (comment), should work normally. Inspection Procedure O-2 INSPECTION PROCEDURE O-2: The ignition switch (IG1) signal is not sent to the ETACS-ECU. CIRCUIT OPERATION - The ETACS-ECU operates various functions according to the input signal from the ignition switch (IG1). - This circuit will work as a backup circuit if the battery circuit to the ETACS-ECU is open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2434 TECHNICAL DESCRIPTION (COMMENT) The ignition switch (IG1) input signal is used to operate the following devices or functions: - Ignition key reminder tone alarm function - Light reminder tone alarm function - Door ajar tone alarm function - Low washer fluid level tone alarm function - Seat belt tone alarm function - Low fuel level tone alarm function - Rolling lock function - Power window timer function - Sunroof timer function - Low washer fluid level warning light - Seat belt warning light - Headlight automatic shutdown function - Turn-signal light - Interior light dimming function If the signal fails, these devices will not work normally. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the ignition switch (IG1) circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect the ETACS-ECU connector C-319 and measure the voltage available at the junction block side of the connector. 2. Turn the ignition switch to the 'ON' position. 3. Measure the voltage between terminal 8 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the ETACS-ECU. The ignition switch (IG1) input signal should be able to be checked and the functions, which are described Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2435 in the "Technical Description (comment),' should work normally. NO : Go to Step 2. STEP 2. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic Aids The ignition switch (IG1) input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 3. Check the wiring harness between ETACS-ECU connector C-319 (terminal 8) and ignition switch (IG1). NOTE: Also check junction block connector C-311 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-311 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between ETACS-ECU connector C-319 (terminal 8) and ignition switch (IG1) in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The ignition switch (IG1) input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Inspection Procedure O-3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2436 INSPECTION PROCEDURE O-3: The key reminder switch signal is not sent to the ETACS-ECU. CIRCUIT OPERATION The ETACS-ECU operates various functions according to the input signal from the key reminder switch. TECHNICAL DESCRIPTION (COMMENT) The key reminder switch input signal is used to operate the following functions or system: - Ignition key reminder tone alarm function - Forgotten key prevention function - Keyless entry system - Interior lights dimming function - Theft-alarm system If the signal fails, these functions or system will not work normally. TROUBLESHOOTING HINTS - The key reminder switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the key reminder switch. Disconnect key reminder switch connector C-201. Then check the continuity. Q: Is the key reminder switch in good condition? YES : Go to Step 2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2437 NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The key reminder switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 2. Check the ground circuit to the key reminder switch. Test at key reminder switch connector C-201. 1. Disconnect the key reminder switch connector C-201 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance between terminal 4 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 5. NO : Go to Step 3. STEP 3. Check the key reminder switch connector C-201 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is key reminder switch connector C-201 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe key reminder switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2438 STEP 4. Check the wiring harness between key reminder switch connector C-201 (terminal 4) and ground. Q: Is the wiring harness between key reminder switch connector C-201 (terminal 4) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The key reminder switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 5. Check the key reminder switch connector C-201 and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are key reminder switch connector C-201 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe key reminder switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2439 STEP 6. Check the wiring harness between key reminder switch connector C-201 (terminal 6) and ETACS-ECU connector C-317 (terminal 30). Q: Is the wiring harness between key reminder switch connector C-201 (terminal 6) and ETACS-ECU connector C-317 (terminal 30) in good condition? YES : Go to Step 7. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The key reminder switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 7. Check for the continuity between key reminder switch connector C-201 terminals 4 and 6. 1. Disconnect key reminder switch connector C-201 and measure the resistance available at the equipment side of the connector. 2. No continuity should exist between key reminder switch connector terminal 4 and each other terminals (except terminal 6), and key reminder switch connector terminal 6 and each other terminals (except terminal.) Q: Does the continuity exist? YES : Replace the ETACS-ECU. The key reminder switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : Replace the key reminder switch. The key reminder switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Inspection Procedure O-4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2440 INSPECTION PROCEDURE O-4: The hazard warning light switch signal is not sent to the ETACS-ECU. CIRCUIT OPERATION The ETACS-ECU operates various functions according to the input signal from the hazard warning light switch. TECHNICAL DESCRIPTION (COMMENT) Hazard warning light switch input signal is used to operate the following device or system: - Hazard warning light - Keyless entry system (registering the encrypted code) If the signal fails, these device or system will not work normally. TROUBLESHOOTING HINTS - The hazard warning light switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2441 STEP 1. Check the hazard warning light switch. Q: Is the hazard warning light switch in good condition? YES : Go to Step 2. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The hazard warning light switch input signal should be able to be checked and the functions, which are described in the "Technical Description (comment),' should work normally. STEP 2. Check the ground circuit to the hazard warning light switch. Test at hazard warning light switch connector C-09. 1. Disconnect the hazard warning light switch connector C-09 and measure the resistance available at the wiring harness side of the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2442 2. Measure the resistance between terminal 2 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 5. NO : Go to Step 3. STEP 3. Check the hazard warning light switch connector C-09 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is hazard warning light switch connector C-09 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic Aids The hazard warning light switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),'should work normally. STEP 4. Check the wiring harness between hazard warning light switch connector C-09 (terminal 2 and ground. Q: Is the wiring harness between hazard warning light switch connector C-09 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2443 connector. Repair the wiring harness as necessary. The hazard warning light switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 5. Check the hazard warning light switch connector C-09 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are hazard warning light switch connector C-09 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The hazard warning light switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 6. Check the wiring harness between hazard warning light switch connector C-09 (terminal 1) and ETACS-ECU connector C-318 (terminal Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2444 55). Q: Is the wiring harness between hazard warning light switch connector C-09 (terminal 1) and ETACS-ECU connector C-318 (terminal 55) in good condition? YES : Replace the ETACS-ECU. The hazard warning light switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The hazard warning light switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Inspection Procedure O-5 INSPECTION PROCEDURE O-5: The fog light switch signal is not sent to the ETACS-ECU. CIRCUIT OPERATION The ETACS-ECU operates the fog lights according to the input signal from the fog light switch. TECHNICAL DESCRIPTION (COMMENT) The fog lights will not work normally if the fog light switch input signal is an error. TROUBLESHOOTING HINTS - The fog light switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2445 STEP 1. Check the fog light switch. Q: Is the fog light switch in good condition? YES : Go to Step 2. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The fog light switch input signal should be able to be checked and the fog lights should work normally. STEP 2. Check the ground circuit to the fog light switch. Test at fog light switch connector C-139. 1. Disconnect the fog light switch connector C-139 and measure the resistance available at the wiring harness side of the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2446 2. Measure the resistance between terminal 7 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 5. NO : Go to Step 3. STEP 3. Check the fog light switch connector C-139 for loose, corroded or damaged terminals, or terminals pushed back in the connector Q: Is fog light switch connector C-139 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe fog light switch input signal should be able to be checked and the fog light should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2447 STEP 4. Check the wiring harness between fog light switch connector C-139 (terminal 7) and ground. NOTE: Also check joint connector C-141 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If joint connector C-141 is damaged, repair or replace the damaged components) Refer to Harness Connector Inspection. Q: Are the wiring harness between fog light switch connector C-139 (terminal 7) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The fog light switch input signal should be able to be checked and the fog lights should work normally. STEP 5. Check the fog light switch connector C-139 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2448 Q: Are fog light switch connector C-139 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The fog light switch input signal should be able to be checked and the fog lights should work normally. STEP 6. Check the wiring harness between fog light switch connector C-139 (terminal 6) and ETACS-ECU connector C-318 (terminal 54). Q: Is the wiring harness between fog light switch connector C-139 (terminal 6) and ETACS-ECU connector C-318 (terminal 54) in good condition? YES : Replace the ETACS-ECU. The fog light switch input signal should be able to be checked and the fog lights should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The fog light switch input signal should be able to be checked and the fog lights should work normally. Inspection Procedure O-6 INSPECTION PROCEDURE O-6: The washer fluid level switch signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2449 CIRCUIT OPERATION The ETACS-ECU operates the low washer fluid level warning light according to the input signal from the washer fluid level switch. TECHNICAL DESCRIPTION (COMMENT) The washer fluid level switch input signal is used to operate the following functions: - Low washer fluid level tone alarm function - Low washer fluid level warning light If the signal fails, these devices will not work normally. TROUBLESHOOTING HINTS - The washer fluid level switch may be defective - The ETACS-ECU may be defective Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2450 - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the washer fluid level switch. Q: Is the washer fluid level switch in good condition? YES : Go to Step 2. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The washer fluid level switch input signal should be able to be checked and the functions, which are described in the "Technical Description (comment),' should work normally. STEP 2. Check the ground circuit to the washer fluid level switch. Test at washer fluid level switch connector A-32. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2451 1. Disconnect the washer fluid level switch connector A-32 and measure the resistance available at the harness side of the connector. 2. Measure the resistance between terminal 1 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 5. NO : Go to Step 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2452 STEP 3. Check the washer fluid level switch connector A-32 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is washer fluid level switch connector A-32 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic AidsThe washer fluid level switch input signal should be able to be checked and the functions, which are described in the "Technical Description (comment),' should work normally. STEP 4. Check the wiring harness between washer fluid level switch connector A-32 (terminal 1) and ground. Q: Are the wiring harness between washer fluid level switch connector A-32 (terminal 1) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The washer fluid level switch input signal should be able to be checked and the functions, which are described in the technical description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2453 STEP 5. Check the washer fluid level switch connector A-32 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are washer fluid level switch connector A-32 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The washer fluid level switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2454 STEP 6. Check the wiring harness between washer fluid level switch connector A-32 (terminal 2) and ETACS-ECU connector C-318 (terminal 57). NOTE: Also check intermediate connectors C-05 and C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connectors C-05 or C-209 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between washer fluid level switch connector A-32 (terminal 2) and ETACS-ECU connector C-318 (terminal 57) in good condition? YES : Replace the ETACS-ECU. The washer fluid level switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2455 connector. Repair the wiring harness as necessary. The washer fluid level switch input signal should be able to be checked and the functions, which are described in the technical description(comment), should work normally. Inspection Procedure O-7 INSPECTION PROCEDURE O-7: The driver's seat belt switch is not sent to the ETACS-ECU. CIRCUIT OPERATION The ETACS-ECU operates various functions according to the input signals from the driver's seat belt switch. TECHNICAL DESCRIPTION (COMMENT) The driver's seat belt switch input signal is used to operate the following functions; seat belt tone alarm function, seat belt warning light. If the input signal is an error, these functions will not work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2456 TROUBLESHOOTING HINTS - The driver's inner seat belt (driver's seat belt switch) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic trouble Code Check Harness STEP 1. Check the driver's seat belt switch. Q: Is the driver's seat belt switch in good condition? YES : Go to Step 2. NO : Replace the driver's inner seat belt. The driver's seat belt switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 2. Check the ground circuit to the driver's seat belt switch. Test at driver's seat belt switch connector D-15. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2457 1. Disconnect driver's seat belt switch connector D-15 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance between terminal 2 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 5. NO : Go to Step 3. STEP 3. Check the driver's seat belt switch connector D-15 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is driver's seat belt switch connector D-15 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The driver's seat belt switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2458 STEP 4. Check the wiring harness between driver's seat belt switch connector D-15 (terminal 2) and ground. Q: Is the wiring harness between driver's seat belt switch connector D-15 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The driver's seat belt switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment) should work normally. STEP 5. Check the driver's seat belt switch connector D-15 and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are driver's seat belt switch connector D-15 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The driver's seat belt switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2459 STEP 6. Check the wiring harness between driver's seat belt switch connector D-15 (terminal 1) and ETACS-ECU connector C-317 (terminal 21). NOTE: Also check intermediate connector C-210 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-210 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between driver's seat belt switch connector D-15 (terminal 1) and ETACS-ECU connector C-317 (terminal 21) in good condition? YES : Replace the ETACS-ECU. The driver's seat belt switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The driver's seat belt switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Inspection Procedure O-8 INSPECTION PROCEDURE O-8: The driver's or passenger's door switches signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2460 CIRCUIT OPERATION The ETACS-ECU operates various functions according to the input signal from the driver's or passenger's door switch. TECHNICAL DESCRIPTION (COMMENT) The driver's and passenger's door switches are used to operate the following devices or systems: - Ignition key reminder tone alarm function (driver's door switch only) - Light reminder tone alarm function (driver's door switch only) - Door ajar tone alarm function - Forgotten key prevention function - Power window timer function - Keyless entry system - Sunroof timer function - Door ajar warning light - Interior light - Theft-alarm system If the signal fails, these devices will not work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2461 TROUBLESHOOTING HINTS - The driver's or passenger's door switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the door switch. Q: Is the door switch in good condition? YES : Go to Step 2. NO : Replace door switch. The driver's and passenger's door switches input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 2. Check the door switch installation state. NOTE: The door switch is grounded to the body through the mounting screws. Remove the cap and measure the resistance between the lower metal part and the ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 3. NO : Check the installation state and repair. The driver's and passenger's door switches input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 3. Verify the location of malfunction. Q: Which door switch signal is not input? Driver's door : Go to Step 4. Passenger's door: Go to Step 6. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2462 STEP 4. Check the driver's door switch connector D-13 and ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are driver's door switch connector D-13and ETACS-ECU connector C-319 in good condition? YES : Go to Step 5. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The driver's door switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2463 STEP 5. Check the wiring harness between driver's door switch connector D-13 (terminal 2) and ETACS-ECU connector C-319 (terminal 10). NOTE: Also check junction block connector C-301 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-301 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Is the wiring harness between the driver's door switch connector D-13 (terminal 2) and ETACS-ECU connector C-319 (terminal 10) in good condition? YES : Replace the ETACS-ECU. The driver's door switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The driver's door switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 6. Check the passenger's door switch connector D-21 and ETACS-ECU connectors C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are passenger's door switch connector D-21 and ETACS-ECU connectors C-318 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The passenger's door switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2464 STEP 7. Check the wiring harness between passenger's door switch connector D-21 (terminal 2) and ETACS-ECU connectors C-318 (terminal 65). NOTE: Also check intermediate connector C-210 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-210 are damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between passenger's door switch connector D-21 (terminal 2) and ETACS-ECU connector C-318 (terminal 65) in good condition? YES : Replace the ETACS-ECU. The passenger's door switch input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The passenger's door switch input signal should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Inspection Procedure O-9 INSPECTION PROCEDURE O-9: The driver's or passenger's door lock key cylinder switch is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2465 CIRCUIT OPERATION The ETACS-ECU uses the input signals from the driver's and passenger's door lock key cylinder switch to operate the following devices or functions. TECHNICAL DESCRIPTION (COMMENT) The driver's and passenger's door lock key cylinder switch input signals is used to operate the following devices or functions: - Central door locking system - Theft-alarm system If the signal fails, these devices will not work normally. TROUBLESHOOTING HINTS - The driver's or passenger's door lock key cylinder switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2466 - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the location of malfunction. Q: Which door key switch signal is not input? Driver's door : Go to Step 2. Passenger's door: Go to Step 8. STEP 2. Check the driver's door lock key cylinder switch. Q: Is the driver's door lock key cylinder switch in good condition? YES : Go to Step 3. NO : Replace it. The input signal from the driver's door lock key cylinder switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 3. Check the driver's door lock key cylinder switch ground circuit at driver's door lock key cylinder switch connector E-14. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2467 1. Disconnect driver's door lock key cylinder switch connector E-14 and measure at the wiring harness side. 2. Measure the resistance between terminal 2 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 6. NO : Go to Step 4. STEP 4. Check the driver's door lock key cylinder switch connector E-14 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is driver's door lock key cylinder switch connector E-14 in good condition? YES : Go to Step 5. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the driver's door lock key cylinder switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2468 STEP 5. Check the wiring harness between driver's door lock key cylinder switch connector E-14 (terminal 2) and ground. NOTE: Also check intermediate connector C-211 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-211 is damaged, repair or replace it. Refer to Harness Connector Inspection. Q: Are the wiring harness between driver's door lock key cylinder switch connector E-14 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the driver's door lock key cylinder switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 6. Check the driver's door lock key cylinder switch connector E-14 and ETACS-ECU connector C-317 for loose, corroded or damaged Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2469 terminals, or terminals pushed back in the connector. Q: Are driver's door lock key cylinder switch connector E-14 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the driver's door lock key cylinder switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 7. Check the wiring harness between driver's door lock key cylinder switch connector E-14 (terminal 1 and 3) and ETACS-ECU connector C-317 (terminal 25 and 42). NOTE: Also check intermediate connector C-211 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-211 is damaged, repair or replace it. Refer to Harness Connector Inspection. Q: Are the wiring harness between driver's door lock key cylinder switch connector E-14 (terminal 1 and 3) and ETACS-ECU connector C-317 (terminal 25 and 42) in good condition? YES : Replace the ETACS-ECU. The input signal from the driver's door lock key cylinder switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the driver's door lock key cylinder switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2470 STEP 8. Check the passenger's door lock key cylinder switch. Q: Is the passenger's door lock key cylinder switch in good condition? YES : Go to Step 9. NO : Replace it. The input signal from the passenger's door lock key cylinder switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2471 STEP 9. Check the passenger's door lock key cylinder switch ground circuit at passenger's door lock key cylinder switch connector E-06. 1. Disconnect passenger's door lock key cylinder switch connector E-06 and measure at the wiring harness side. 2. Measure the resistance between terminal 2 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 12. NO: Go to Step 10. STEP 10. Check the passenger's door lock key cylinder switch connector E-06 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is passenger's door lock key cylinder switch connector E-06 in good condition? YES: Go to Step 11. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The input signal from the passenger's door lock key cylinder switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2472 STEP 11. Check the wiring harness between passenger's door lock key cylinder switch connector E-06 (terminal 2) and ground. NOTE: Also check intermediate connector C-213 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-213 is damaged, repair or replace it. Refer to Harness Connector Inspection. Q: Are the wiring harness between passenger's door lock key cylinder switch connector E-06 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the passenger's door lock key cylinder switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 12. Check the passenger's door lock key cylinder switch connector E-06 and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are passenger's door lock key cylinder switch connector E-06 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 13. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the passenger's door lock key cylinder switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2473 STEP 13. Check the wiring harness between passenger's door lock key cylinder switch connector E-06 (terminal 1 and 3) and ETACS-ECU connector C-317 (terminal 42 and 31). NOTE: Also check intermediate connector C-213 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-213 is damaged, repair or replace it. Refer to Harness Connector Inspection. Q: Are the wiring harness between passenger's door lock key cylinder switch connector E-06 (terminal 1 and 3) and ETACS-ECU connector C-213 (terminal 42 and 31) in good condition? YES : Replace the ETACS-ECU. The input signal from the passenger's door lock key cylinder switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the passenger's door lock key cylinder switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Inspection Procedure O-10 INSPECTION PROCEDURE O-10: The driver's or passenger's door lock actuator switch is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2474 CIRCUIT OPERATION The ETACS-ECU uses the input signal from the driver's, passenger's, rear and back door lock actuator switch to operate the following functions. TECHNICAL DESCRIPTION (COMMENT) The input signal from the driver's door lock actuator switch is used to operate the following systems or functions: - Central door locking system - Forgotten key prevention function . - Rolling lock function - Keyless entry system - Interior light dimming function - Theft-alarm system If the signal fails, these systems or function will not work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2475 TECHNICAL DESCRIPTION (COMMENT) The input signal from the passenger's door lock actuator switch is used to operate the following systems or functions: - Forgotten key prevention function - Rolling lock function - Theft-alarm system If the signal fails, these systems or function will not work normally. TROUBLESHOOTING HINTS - The driver's or passenger's door latch assembly may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the location of malfunction. Q: Which door lock actuator switch signal is not input? Driver's door : Go to Step 2. Passenger's door: Go to Step 8. STEP 2. Check the driver's door lock actuator switch. Q: Is the driver's door lock actuator switch in good condition? YES : Go to Step 3. NO : Replace it. The input signal from the driver's door lock actuator switch should be able to be checked and the functions, which are described in Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2476 the Technical Description (comment),' should work normally. STEP 3. Check the ground circuit to the driver's door lock actuator switch. Test at driver's door lock actuator switch connector E-13. 1. Disconnect driver's door lock actuator switch connector E-13 and measure the resistance available at the wiring harness side. 2. Measure the resistance between terminal 1 and ground of the connector. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 6. NO : Go to Step 4. STEP 4. Check the driver's door lock actuator switch connector E-13 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is driver's door lock actuator switch connector E-13 in good condition? YES : Go to Step 5. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the driver's door lock actuator switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2477 STEP 5. Check the wiring harness between driver's door lock actuator switch connector E-13 (terminal 1) and ground. NOTE: Also check intermediate connector C-211 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-211 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between driver's door lock actuator switch connector E-13 (terminal 1) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the driver's door lock actuator switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 6. Check the driver's door lock actuator switch connector E-13 and ETACS-ECU connector C-317 for loose, corroded or damaged Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2478 terminals, or terminals pushed back in the connector. Q: Is driver's door lock actuator switch connector E-13 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the driver's door lock actuator switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 7. Check the wiring harness between driver's door lock actuator switch connector E-13 (terminal 2 and 3) and ETACS-ECU connector C-317 (terminal 36 and 35). NOTE: Also check intermediate connector C-211 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-211 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between driver's door lock actuator switch connector E-13 (terminal 2 and 3) and ETACS-ECU connector C-317 (terminal 36 and 35) in good condition? YES : Replace the ETACS-ECU. The input signal from the driver's door lock actuator switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the driver's door lock actuator switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2479 STEP 8. Check the passenger's door lock actuator switch. Q: Is the passenger's door lock actuator switch in good condition? YES : Go to Step 9. NO : Replace it. The input signal from the passenger's door lock actuator switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2480 STEP 9. Check the ground circuit to the passenger's door lock actuator switch. Test at passenger's door lock actuator switch connector E-07. 1. Disconnect passenger's door lock actuator switch connector E-07 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance between terminal 3 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 12. NO: Go to Step 10. STEP 10. Check the passenger's door lock actuator switch connector E-07 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is passenger's door lock actuator switch connector E-07 in good condition? YES: Go to Step 11. NO : Repair or replace the damaged components). Refer to Harness Connector Inspection. The input signal from the passenger's door lock actuator switch should be able to be checked and the functions, which are described in the "Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2481 STEP 11. Check the wiring harness between passenger's door lock actuator switch connector E-07 (terminal 3) and ground. NOTE: Also check intermediate connector C-213 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-213 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between passenger's door lock actuator switch connector E-07 (terminal 3) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the passenger's door lock actuator switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 12. Check the passenger's door lock actuator switch connector E-07 and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is passenger's door lock actuator switch connector E-07 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 13. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the passenger's door lock actuator switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2482 STEP 13. Check the wiring harness between passenger's door lock actuator switch connector E-07 (terminal 2) and ETACS-ECU connector C-317 (terminal 43). NOTE: Also check intermediate connector C-213 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-213 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between passenger's door lock actuator switch connector E-07 (terminal 2) and ETACS-ECU connector C-317 (terminal 43) in good condition? YES : Replace the ETACS-ECU. The input signal from the passenger's door lock actuator switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the passenger's door lock actuator switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Inspection Procedure O-11 INSPECTION PROCEDURE O-11: The door lock switch (incorporated in power window main switch and power window sub switch) signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2483 CIRCUIT OPERATION The ETACS-ECU uses the input signal from the door lock switch to operate the central door locking system. TECHNICAL DESCRIPTION (COMMENT) The door lock switch input signal is used to operate the central door locking system. If the signal fails, the door will not be locked or unlocked when the door lock switch is operated. TROUBLESHOOTING HINTS - The power window main switch or power window sub switch (door lock switch) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the location of malfunction. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2484 Q: Which door lock switch signal is not input? Power window main switch (Driver's door): Go to Step 2. Power window sub switch (Passenger's door): Go to Step 8. STEP 2. Check the door lock switch (power window main switch). Q: Is the door lock switch (power window main switch) in good condition? YES : Go to Step 3. NO : Replace the power window main switch. The door lock switch input signal should be able to be checked and the central door locking system should work normally. STEP 3. Check the ground circuit to the power window main switch. Test at power window main switch connector E-12. 1. Disconnect power window main switch connector E-12 and measure the resistance available at the wiring harness side of the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2485 2. Measure the resistance between terminal 9 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 6. NO : Go to Step 4. STEP 4. Check the power window main switch connector E-12 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is power window main switch connector E-12 in good condition? YES : Go to Step 5. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection . The door lock switch input signal should be able to be checked and the central door locking system should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2486 STEP 5. Check the wiring harness between power window main switch connector E-12 (terminal 9) and ground. NOTE: Also check intermediate connector C-211 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-211 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between power window main switch connector E-12 (terminal 9) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The door lock switch input signal should be able to be checked and the central door locking system should work normally. STEP 6. Check the power window main switch connector E-12 and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are power window main switch connector E-12 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 7. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The door lock switch input signal should be able to be checked and the central door locking system should work normally. STEP 7. Check the wiring harness between power window main switch connector E-12 (terminal 3 and 10) and ETACS-ECU connector C-317 (terminal 33 and 34). NOTE: Also check intermediate connector C-211 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2487 connector C-211 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between power window main switch connector E-12 (terminal 3 and 10) and ETACS-ECU connector C-317 (terminal 33 and 34) in good condition? YES : Replace the ETACS-ECU. The door lock switch input signal should be able to be checked and the central door locking system should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The door lock switch input signal should be able to be checked and the central door locking system should work normally. STEP 8. Check the door lock switch (power window sub switch). Q: Is the door lock switch (power window sub switch) in good condition? YES : Go to Step 9. NO : Replace the power window sub switch. The door lock switch input signal should be able to be checked and the central door locking system should work normally. STEP 9. Check the ground circuit to the power window sub switch. Test at power window sub switch connector E-05. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2488 1. Disconnect power window sub switch connector E-05 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance between terminal 2 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 12. NO: Go to Step 10. STEP 10. Check the power window sub switch connector E-05 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is power window sub switch connector E-05 in good condition? YES : Go to Step 11. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The door lock switch input signal should be able to be checked and the central door locking system should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2489 STEP 11. Check the wiring harness between power window sub switch connector E-05 (terminal 5) and ground. NOTE: Also check intermediate connector C-213 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-213 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection . Q: Are the wiring harness between power window sub switch connector E-05 (terminal 5) and ground in good condition? YES : No action is necessary and testing is complete. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The door lock switch input signal should be able to be checked and the central door locking system should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2490 STEP 12. Check the power window sub switch connector E-05 and ETACS-ECU connector C-317 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is power window sub switch connector E-05 and ETACS-ECU connector C-317 in good condition? YES : Go to Step 13. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The door lock switch input signal should be able to be checked and the central door locking system should work normally. STEP 13. Check the wiring harness between power window sub switch connector E-05 (terminal 1 and 3) and ETACS-ECU connector C-317 (terminal 33 and 34). NOTE: Also check intermediate connector C-213 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-213 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between power window sub switch connector E-05 (terminal 1 and 3) and ETACS-ECU connector C-317 (terminal 33 and 34) in good condition? YES : Replace the ETACS-ECU. The door lock switch input signal should be able to be checked and the central door locking system should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The door lock switch input signal should be able to be checked and the central door locking system should work normally. Inspection Procedure O-12 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2491 INSPECTION PROCEDURE O-12: The trunk lid latch switch signal is not sent to the ETACS-ECU. CIRCUIT OPERATION The ETACS-ECU uses the input signal from the trunk lid latch switch to operate the following functions. TECHNICAL DESCRIPTION (COMMENT) The trunk lid latch switch input signal is used to operate the following functions: - Door ajar warning light - Theft-alarm system If the signal fails, these function will not work normally. TROUBLESHOOTING HINTS - The trunk lid latch may be defective Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2492 - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the trunk lid latch switch. Q: Is the trunk lid latch switch in good condition? YES : Go to Step 2. NO : Replace it. The input signal from the trunk lid latch switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 2. Check the ground circuit to the trunk lid latch switch. Test at trunk lid latch switch connector F-05. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2493 1. Disconnect trunk lid latch switch connector F-05 and measure the resistance available at the wiring harness side of the connector. 2. Measure the resistance between terminal 2 and ground. - The resistance should equal 2 ohms or less. Q: Is the measured resistance 2 ohms or less? YES : Go to Step 5. NO : Go to Step 3. STEP 3. Check the trunk lid latch switch connector F-05 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is trunk lid latch switch connector F-05 in good condition? YES : Go to Step 4. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the trunk lid latch switch should be able to be checked and the functions, which are described in the Technical Description (comment),' should work normally. STEP 4. Check the wiring harness between trunk lid latch switch connector F-05 (terminal 2) and ground. Q: Is the wiring harness between trunk lid latch switch connector F-05 (terminal 2) and ground in good condition? YES : No action is necessary and testing is complete. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2494 NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the trunk lid latch switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 5. Check the trunk lid latch switch connector F-05 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are trunk lid latch switch connector F-05 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input, signal from the trunk lid latch switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),'should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2495 STEP 6. Check the wiring harness between trunk lid latch switch connector F-05 (terminal 1) and ETACS-ECU connector C-318 (terminal 37). NOTE: Also check intermediate connector C-210 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-210 is damaged, repair or replace the damaged components) as described in Harness Connector Inspection. Q: Are the wiring harness between trunk lid latch switch connector F-05 (terminal 1) and ETACS-ECU connector C-318 (terminal 37) in good condition? YES : Replace the ETACS-ECU. The input signal from the trunk lid latch switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the trunk lid latch switch should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Inspection Procedure O-13 INSPECTION PROCEDURE O-13: The speed sensor signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2496 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2497 Connectors Manual Transmission Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2498 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2499 Connectors Automatic Trans Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2500 02 Sebring/Stratus CIRCUIT OPERATION The ETACS-ECU operates various functions according to the input signal from the speed sensor. TECHNICAL DESCRIPTION (COMMENT) The speed sensor input signal is used to operate the following device or system: - Door ajar tone alarm function - Rolling lock function - Windshield intermittent wiper If the signal fails, these device or system will not work normally. TROUBLESHOOTING HINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2501 - The speed sensor may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the speedometer operation. Q: Does the speedometer work normally? YES : Go to Step 2. NO : Solve the problem first. Refer to Combination Meter. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2502 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2503 pushed back in the connector If intermediate connectors B-106 or C-25 or joint connector C-140 are damaged, repair or replace the damaged component(s) as described in Harness Connector Inspection. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2504 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2505 CIRCUIT OPERATION The ETACS-ECU uses the input signal from the column switch (turn-signal light and lighting switch) to operate various functions. TECHNICAL DESCRIPTION (COMMENT) The column switch (turn-signal light and lighting switch) input signal is used to operate the following devices or functions: - Light reminder tone alarm function - Headlight - Turn-signal light - Fog light If the signal fails, these devices will not work normally. TROUBLESHOOTING HINTS - The column switch (turn-signal light and lighting switch) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the ignition switch positions. Q: Does a diagnostic trouble code set when the ignition switch is at any of the positions? YES: Carry out the troubleshooting by referring to the Diagnostic Trouble Code Chart. NO: Go to Step 2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2506 STEP 2. Check the turn-signal light and lighting switch. Q: Is the turn-signal light and lighting switch in good condition? YES: Go to Step 3. NO : Replace it. The input signal from the column switch (turn-signal light and lighting switch) should be able to be checked and the functions, which are described in the "Technical Description (comment)," should work normally. STEP 3. Replacement of ECU 1. Replace the column switch. 2. The input signal from the column switch (turn-signal light and lighting switch) should be able to be checked and the functions, which are described in the "Technical Description (comment)," should work normally. Q: Is the input signal from the column switch (turn-signal light and lighting switch) input normally? YES : No action is necessary and testing is complete. NO : Replace the ETACS-ECU. The input signal from the column switch (turn-signal light and lighting switch) should be able to be checked and the functions, which are described in the "Technical Description (comment)," should work normally. Inspection Procedure O-15 INSPECTION PROCEDURE O-15: Column switch: The windshield mist wiper switch, windshield intermittent wiper switch, windshield low-speed wiper switch, windshield high-speed wiper switch or windshield washer switch signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2507 CIRCUIT OPERATION The ETACS-ECU uses the input signal from the column switch (windshield wiper and washer switch) to operate various functions. TECHNICAL DESCRIPTION (COMMENT) The column switch (windshield wiper and washer switch) input signal is used to operate the windshield wiper and washer. If the signal fails, windshield wiper and washer will not work normally. TROUBLESHOOTING HINTS - The column switch (windshield wiper and washer switch) may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the ignition switch positions. Q: Does a diagnostic trouble code set when the ignition switch is at any of the positions? YES: Carry out the troubleshooting by referring to the Diagnostic Trouble Code Chart. See: NO: Go to Step 2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2508 STEP 2. Check the windshield wiper and washer switch. Q: Is the windshield wiper and washer switch in good condition? YES: Go to Step 3. NO: Replace it. The input signal from the column switch (windshield wiper and washer switch) should be able to be checked and the windshield wiper and washer should work normally. STEP 3. Replacement of ECU 1. Replace the column switch (turn-signal light and lighting switch). 2. The input signal from the column switch (windshield wiper and washer switch) should be able to be checked and the windshield wiper and washer should work normally. Q: Is the input signal from the column switch (windshield wiper and washer switch) input normally? YES: No action is necessary and testing is complete. NO: Replace the ETACS-ECU. The input signal from the column switch (windshield wiper and washer switch) should be able to be checked and the windshield wiper and washer should work normally. Inspection Procedure O-16 INSPECTION PROCEDURE O-16: The windshield intermittent wiper interval adjusting knob signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2509 CIRCUIT OPERATION The ETACS-ECU calculates the windshield intermillent wiper interval according to the resistance of the windshield intermittent wiper interval adjusting knob, which is incorporated in the column switch (windshield wiper and windshield washer switch). TECHNICAL DESCRIPTION (COMMENT) If the windshield intermittent wiper interval adjusting knob is defective, the windshield intermittent wiper interval can not be adjusted. TROUBLESHOOTING HINTS - The column switch may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector. DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2510 STEP 1. Check the windshield intermittent wiper interval adjusting knob and column switch body. Check the resistance at terminal numbers 27 and 28. The resistance should change smoothly from approximately 0 ohm ("FAST" position) to approximately 1 kilohm ("SLOW" position). Q: Is the windshield intermittent wiper interval adjusting knob in good condition? YES : Go to Step 2. NO : Replace the it. Check that the input signal from the windshield intermittent wiper interval adjusting knob can be checked and the wiper interval can be adjusted. STEP 2. Check the column switch connector C-203 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is column switch connector C-203 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. Check that the input signal from the windshield intermittent wiper interval adjusting knob can be checked and the wiper interval can be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2511 STEP 3. Check the wiring harness between column switch connector C-203 (terminal 6) and ETACS-ECU connector C-318 (terminal 66). Q: Is the wiring harness between column switch connector C-203 (terminal 6) and ETACS-ECU connector C-318 (terminal 66) in good condition? YES : Go to 4. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Check that the input signal from the windshield intermittent wiper interval adjusting knob can be checked and the wiper interval can be adjusted. STEP 3. Replacement of ECU 1. Replace the ETACS-ECU. 2. Check that the input signal from the windshield intermittent wiper interval adjusting knob can be checked and the wiper interval can be adjusted. Q: Is the input signal from the windshield intermittent wiper interval adjusting knob input normally? YES : No action is necessary and testing is complete. NO : Replace the column switch. Check that the input signal from the windshield intermittent wiper interval adjusting knob can be checked and the wiper interval can be adjusted. Inspection Procedure O-17 INSPECTION PROCEDURE O-17: Transmitter: The lock, unlock, trunk or panic switch signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2512 03-04 Sebring/Stratus 02 Sebring/Stratus CIRCUIT OPERATION The ETACS-ECU receives an input signal from the transmitter through its built-in receiver, and evaluates the signal to operate various functions. TECHNICAL DESCRIPTION (COMMENT) The transmitter input signal is used to operate the following Systems; - Keyless entry system - Theft-alarm system If the signal fails, these systems will not work normally. TROUBLESHOOTING HINTS - The transmitter may be defective - The ETACS-ECU may be defective DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Register the transmitter. Register the transmitter (Refer to Keyless Entry System On-vehicle Service - Encrypted Code Registration Method.) Q: Is the transmitter registered successfully? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2513 YES : The transmitter input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : Go to Step 2. STEP 2. Check the transmitter battery. Measure the transmitter battery's voltage. - The value should be approximately 2.5 - 3.2 volts. Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 3. NO : Replace the battery. If the transmitter is registered successfully, the transmitter input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. STEP 3. Check the transmitter. 1. Use an other transmitter to register the secret code. (Refer to keyless Entry System - On-vehicle Service - Encrypted Code Registration Method.) Q: Is the transmitter registered successfully? YES : The transmitter input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. NO : Replace the ETACS-ECU. The transmitter input signal should be able to be checked and the functions, which are described in the 'Technical Description (comment),' should work normally. Inspection Procedure O-18 INSPECTION PROCEDURE O-18: Sunroof switch: The open or close switch signal is not sent to the ETACS-ECU. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2514 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2515 03-04 Sebring/Stratus Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2516 02 Sebring/Stratus CIRCUIT OPERATION The ETACS-ECU receives a signal from the sunroof switch through the sunroof motor assembly, and sends the input signal to the data link connector. TECHNICAL DESCRIPTION (COMMENT) If the SWS communication line between the sunroof motor assembly and the ETACS-ECU is defective, the sunroof switch input signal can not be checked even if the sunroof is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2517 TROUBLESHOOTING HINTS - The sunroof switch may be defective - The sunroof motor assembly may be defective - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Verify the sunroof operation. Q: Does the sunroof work normally? YES : Go to Step 2. NO : Solve the problem first. Refer to Inspection Procedure F-1. STEP 2. Check the sunroof motor assembly connector D-08 and ETACS-ECU connector C-318 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Are sunroof motor assembly connector D-08 and ETACS-ECU connector C-318 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The input signal from the sunroof switch should be able to be checked and the sunroof should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2518 STEP 3. Check the wiring harness between sunroof motor assembly connector D-08 (terminal 10) and ETACS-ECU connector C-318 (terminal 59). NOTE : Also check intermediate connector C-28 and joint connector C-141 for loose, corroded, or damaged terminals, or terminals pushed back in the connector If intermediate connector C-28 or joint connector C-141 are damaged, repair or replace the damaged component(s) Refer to Harness Connector Inspection. Q: Are the wiring harness between sunroof motor assembly connector D-08 (terminal 10) and ETACS-ECU connector C-318 (terminal 59) in good condition? YES : Go to Step 4. NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The input signal from the sunroof switch should be able to be checked and the sunroof should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2519 STEP 4. Replacement of ECU 1. Replace the sunroof motor assembly. 2. The input signal from the sunroof switch should be able to be checked and the sunroof should work normally Q: Is the input signal from the sunroof switch input normally? YES : No action is necessary and testing is complete. NO : Replace the ETACS-ECU. The input signal from the sunroof switch should be able to be checked and the sunroof should work normally. Inspection Procedure O-19 INSPECTION PROCEDURE O-19: ETACS-ECU does not receive a interior light loaded signal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2520 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2521 Connectors CIRCUIT OPERATION The ETACS-ECU operates the following equipment or functions by the interior light loaded signal: TECHNICAL DESCRIPTION (COMMENT) The ETACS-ECU operates the following equipment or functions by the interior light loaded signal: - Interior lights (dome light and rear personal lights and foot lights and trunk light) - Interior light automatic shutoff function If the signal is not normal, the equipment or functions do not work normally. TROUBLESHOOTING HINTS - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2522 STEP 1. Check the battery power supply circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect ETACS-ECU connector C-319 and measure the voltage available at the junction block side of the connector. 2. Measure the voltage between terminal 20 and ground. The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 4 NO : Go to Step 2. STEP 2. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 3. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2523 STEP 3. Check the wiring harness between ETACS-ECU connector C-319 (terminal 20) and battery. NOTE : Also check junction block connector C-312, joint connector C-141 and intermediate connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-312, joint connector C-141 or intermediate connector C-209 is damaged, repair or replace the damaged component(s) as described in Harness Connector Inspection. Q: Is the wiring harness between ETACS-ECU connector C-319 (terminal 20) and the battery in good condition? YES : No action is necessary and testing is complete. NO : Repair the wiring harness. If the functions or equipment, which are described in 'CIRCUIT OPERATION', work normally, the interior light loaded signal should be normal. STEP 4. Check the ignition switch (IG1) circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2524 1. Disconnect ETACS-ECU connector C-319 and measure the voltage available at the junction block side of the connector. 2. Turn the ignition switch to the 'ON' position. 3. Measure the voltage between terminal 8 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Go to Step 7. NO : Go to Step5. STEP 5. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 6. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2525 STEP 6. Check the wiring harness between ETACS-ECU connector C-319 (terminal 8) and the ignition switch (IG1). NOTE : Also check junction block connector C-311 for loose, corroded, or damaged terminals, or terminals pushed back In the connector. If junction block connector C-311 is damaged, repair or replace the damaged component(s) as described in Harness Connector Inspection. Q: Is the wiring harness between ETACS-ECU connector C- 319 (terminal 8) and the ignition switch (IG1) in good condition? YES : No action is necessary and testing is complete. NO : Repair the wiring harness. If the functions or equipment, which are described in 'CIRCUIT OPERATION', work normally, the interior light loaded signal should be normal. STEP 7. Check the ignition switch (ACC) circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect ETACS-ECU connector C-31 9 and measure the voltage available at the junction block side of the connector. 2. Turn the ignition switch to the 'ACC' position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2526 3. Measure the voltage between terminal 4 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the ETACS-ECU. If the functions or equipment, which are described in 'CIRCUIT OPERATION', work normally, the interior light loaded signal should be normal. NO : Go to Step 8. STEP 8. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 9. NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. The functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2527 STEP 9. Check the wiring harness between ETACS-ECU connector C-319 (terminal 4) and the ignition switch (ACC). NOTE : Also check junction block connector C-312 and intermediate connector C-209 for loose, corrode 4, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-312 and intermediate connector C-209 are damaged, repair or replace the damaged component(s) as described In Harness Connector Inspection. Q: Is the wiring harness between ETACS-ECU connector C-319 (terminal 4) and ignition switch (ACC) in good condition? YES : No action is necessary and testing is complete. NO : Repair the wiring harness. If the functions or equipment, which are described in 'CIRCUIT OPERATION', work normally, the interior light loaded signal should be normal. Inspection Procedure P-1 INSPECTION PROCEDURE P-1: Check the circuit (power supply line) from the battery to the ETACS - ECU. ETACS-ECU Power Supply Circuit Refer to Inspection Procedure A-1 See: Diagnosis By Symptom/Symptom Procedures. CIRCUIT OPERATION The ETACS-ECU is always energized by the battery. TECHNICAL DESCRIPTION (COMMENT) If that power supply circuit is defective, the circuit flowing through the ignition switch (IG1) will function as a backup circuit. In this case, the following functions will not work when the ignition switch is at 'LOCK' (OFF) position: - Ignition key reminder tone alarm function - Light reminder tone alarm function - Central door locking system - Hazard warning light - Interior light automatic shutoff function - Interior light dimming function - Theft-alarm system TROUBLESHOOTING HINTS - The ETACS-ECU may be defective - The wiring harness or connectors may have loose, corroded, or damaged terminals, or terminals pushed back in the connector Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2528 DIAGNOSIS Required Special Tools: - MB991223: Test Harness Set - MB991502: Scan Tool (MUT-II) - MB991529: Diagnostic Trouble Code Check Harness STEP 1. Check the battery power supply circuit to the ETACS-ECU. Test at ETACS-ECU connector C-319. 1. Disconnect the ETACS-ECU connector C-319 and measure the voltage available at the junction block side of the connector. 2. Measure the Voltage between terminal 20 and ground. - The voltage should equal approximately 12 volts (battery positive voltage). Q: Is the measured voltage approximately 12 volts (battery positive voltage)? YES : Replace the ETACS-ECU. The functions, which are described in the 'Technical Description (comment),' should work normally. NO : Go to Step 2. STEP 2. Check the ETACS-ECU connector C-319 for loose, corroded or damaged terminals, or terminals pushed back in the connector. Q: Is ETACS-ECU connector C-319 in good condition? YES : Go to Step 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2529 NO : Repair or replace the damaged component(s). Refer to Harness Connector Inspection. See: Diagrams/Diagnostic Aids The functions, which are described in the 'Technical Description (comment),'should work normally. STEP 3. Check the wiring harness between ETACS-ECU connector C-319 (terminal 20) and battery. NOTE : Also check junction block connector C-312, joint connector C-141 and intermediate connector C-209 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If junction block connector C-312, joint connector C-141 and intermediate connector C-209 are damaged, repair or replace the damaged component(s) as described in Harness Connector Inspection. See: Diagrams/Diagnostic Aids Q: Are the wiring harness between ETACS-ECU connector C-319 (terminal 20) and battery in good condition? YES : No action is necessary and testing is complete. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2530 NO : The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. The functions, which are described in the 'Technical Description (comment),' should work normally. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2531 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2532 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2533 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2534 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 2535 Special Tools Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2541 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2542 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2543 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2544 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2545 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2546 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2547 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2562 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2563 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2567 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation TROUBLE CODE DIAGNOSIS Among the on-board diagnostic items, a Malfunction Indicator Lamp (SERVICE ENGINE SOON or Check Engine Lamp) illuminates to notify the driver of an emission control malfunction. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated oxygen sensor output voltage V .............................................................................................. ...................................................................... 0.6 - 1.0 Heated oxygen sensor heater resistance Q ... .............................................................................................................................................................. .................................................... 4.5 - 8.0 .......................................................................................... .............................................................................................................................. 11 - 18 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2577 Oxygen Sensor: Locations View G Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2578 View b Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2579 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2580 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR CHECK Required Special Tools: - MB991658: Test Harness Set - MD998464: Test Harness 1. Using the scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MD998464 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [4.5 - 8.0 Ohm at 20 °C (68 °F) between terminal No.1 (red clip of special tool) and terminal No.3 (blue clip of special tool) on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.1 (red clip) of the heated oxygen sensor connector to the positive battery terminal and terminal No.3 (blue clip) to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.2 (black clip) and terminal No.4 (white clip). 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2581 NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. 1. Using scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MB991658 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [11 - 18 Ohm at 20 °C (68 °F) between terminal No.5 and terminal No.6 on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.5 of the heated oxygen sensor connector to the positive battery terminal and terminal No.6 to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.3 and terminal No.4. 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2582 Oxygen Sensor: Service and Repair REMOVAL AND INSTALLATION Removal And Installation Required Special - MD998770: Oxygen Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2583 Use special tool MD998770 to remove the oxygen sensor. INSTALLATION SERVICE POINT >>A<< RIGHT BANK HEATED OXYGEN SENSOR (FRONT)/RIGHT BANK HEATED OXYGEN SENSOR (REAR)/LEFT BANK HEATED OXYGEN SENSOR (REAR)/HEATED OXYGEN SENSOR (REAR) INSTALLATION Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2592 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2593 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Control - PCM Initialization Procedure > Page 2594 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding Engine Control Module: Locations Grounding Grounding Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Grounding > Page 2597 Engine Control Module: Locations ECM/PCM Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Terminal Voltage Check Chart - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2600 Terminal Voltage Check Chart - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2601 Terminal Voltage Check Chart - Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2602 Terminal Voltage Check Chart - Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 2603 Terminal Voltage Check Chart - Part 5 TERMINAL VOLTAGE CHECK CHART Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2607 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2612 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2613 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2617 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2618 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2619 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2620 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications Engine Coolant Temperature (ECT) Sensor: Electrical Specifications ITEM .................................................................................................................................................... ............................................ STANDARD VALUE Engine coolant temperature sensor resistance kOhm -20 °C (-4 °F) ............................................................................................................................ .................................................................................. 14 - 17 0 °C (32 °F) .......................................... .............................................................................................................................................................. ..... 5.1 - 6.5 20 °C (86 °F) ................................................................................................................... ......................................................................................... 2.1 - 2.7 40 °C (104 °F) ............................. .............................................................................................................................................................. ............... 0.9 - 1.3 60 °C (140 °F) ....................................................................................................... ............................................................................................... 0.48 - 0.68 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Electrical Specifications > Page 2625 Sealants And Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2626 Engine Coolant Temperature (ECT) Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2627 Engine Coolant Temperature (ECT) Sensor: Testing and Inspection ENGINE COOLANT TEMPERATURE SENSOR CHECK CAUTION: Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Drain engine coolant, then remove the engine coolant temperature sensor. 2. With the temperature sensing portion of engine coolant temperature sensor immersed in hot water, check the resistance. Standard value: 14 - 17 kOhm @ -20 °C (-4 °F) 5.1 - 6.5 kOhm @ 0 °C (32 °F) 2.1 - 2.7 kOhm @ 20 °C (68 °F) 0.9 - 1.3 kOhm @ 40 °C (104 °F) 0.48 - 0.68 kOhm @ 60 °C (140 °F) 0.26 - 0.36 kOhm @ 80 °C (176 °F) 3. If resistance deviates from the standard value greatly, replace the sensor. 4. Apply 3M AAD part number 8731 or equivalent to threaded portion. 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 ± 10 Nm (22 ± ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Coolant Temperature (ECT) Sensor <--> [Coolant Temperature Sensor/Switch (For Computer)] > Component Information > Specifications > Page 2628 Engine Coolant Temperature (ECT) Sensor: Service and Repair SEALANTS AND ADHESIVES ITEM .................................................................................................. .......................................................................................... SPECIFIED SEALANT Engine coolant temperature sensor threaded portion ....................................................................................................................................... MOPAR® Part No. 4318031or equivalent Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2639 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2640 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2641 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2642 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2643 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2644 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2655 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2656 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2657 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2658 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Engine Speed Sensor: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations View a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2665 Fuel Tank Pressure Sensor: Testing and Inspection FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK 1. Disconnect the fuel tank differential pressure sensor connector and connect special tool MB991348 between the terminals of the disconnected connector. 2. Turn the ignition switch to "ON" and measure the output voltage between terminals 2 and 3. Standard value: 2.0 - 3.0 V Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2666 Special Tools Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Intake Air Temperature (IAT) Sensor: Specifications Intake air temperature sensor resistance kOhm .................................................................................................................................. STANDARD VALUE -20 °C (-4 °F) ....................................................................................................................................... ....................................................................... 13 - 17 0 °C (32 °F) ..................................................... ......................................................................................................................................................... 5.3 - 6.7 20 °C (86° F) ......................................................................................................................... ................................................................................... 2.3 - 3.0 40 °C (104 °F) ................................... .............................................................................................................................................................. ......... 1.0 - 1.5 60 °C (140 °F) ............................................................................................................. ......................................................................................... 0.56 - 0.76 80 °C (176 °F) ......................... .............................................................................................................................................................. ............... 0.30 - 0.42 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2670 Intake Air Temperature (IAT) Sensor: Locations The Intake Air Temperature sensor is incorporated into the Mass Airflow Sensor and is not serviceable seperately. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2671 Intake Air Temperature (IAT) Sensor: Testing and Inspection INTAKE AIR TEMPERATURE SENSOR CHECK 1. Disconnect the volume air flow sensor connectors. 2. Measure resistance between terminals 5 and 6. Standard value: 13 - 17 kohm @ -20 °C (-4 °F) 5.3 - 6.7 kohm @ 0 °C (32 °F) 2.3 - 3.0 kohm @ 20 °C (68 °F) 1.0 - 1.5 kohm @ 40 °C (104 °F) 0.56 - 0.76 kohm @ 60 °C (140 °F) 0.30 - 0.42 kohm @ 80 °C (176 °F) 3. If not within specifications, replace the volume air flow sensor. 4. Measure resistance while heating the sensor using a hair dryer. Normal condition: TEMPERATURE RESISTANCE (kohm) Higher Smaller 5. If resistance does not decrease as heat increases, replace the volume air flow sensor assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2694 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2695 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2696 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2697 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2698 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 2699 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Heated oxygen sensor output voltage V .............................................................................................. ...................................................................... 0.6 - 1.0 Heated oxygen sensor heater resistance Q ... .............................................................................................................................................................. .................................................... 4.5 - 8.0 .......................................................................................... .............................................................................................................................. 11 - 18 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2706 Oxygen Sensor: Locations View G Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2707 View b Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2708 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2709 Oxygen Sensor: Testing and Inspection HEATED OXYGEN SENSOR CHECK Required Special Tools: - MB991658: Test Harness Set - MD998464: Test Harness 1. Using the scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MD998464 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [4.5 - 8.0 Ohm at 20 °C (68 °F) between terminal No.1 (red clip of special tool) and terminal No.3 (blue clip of special tool) on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.1 (red clip) of the heated oxygen sensor connector to the positive battery terminal and terminal No.3 (blue clip) to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.2 (black clip) and terminal No.4 (white clip). 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2710 NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. 1. Using scan tool MB991502, observe HO(2)S reading. If values are unsatisfactory, or if Scan tool is not available, use the following procedure: 1. Disconnect the heated oxygen sensor connector and connect special tool MB991658 to the connector on the heated oxygen sensor side. 2. Make sure that there is continuity [11 - 18 Ohm at 20 °C (68 °F) between terminal No.5 and terminal No.6 on the heated oxygen sensor connector 3. If there is no continuity, replace the heated oxygen sensor. 4. Warm up the engine until engine coolant is 80 °C (176 °F) or higher. CAUTION: Be very careful when connecting the jumper wires; incorrect connection can damage the heated oxygen sensor. 5. Use the jumper wires to connect terminal No.5 of the heated oxygen sensor connector to the positive battery terminal and terminal No.6 to the negative battery terminal. 6. Connect a digital voltage meter between terminal No.3 and terminal No.4. 2. While repeatedly revving the engine, measure the heated oxygen sensor output voltage. Standard value: 3. If the sensor is defective, replace the heated oxygen sensor. NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust Pipe and Main Muffler. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2711 Oxygen Sensor: Service and Repair REMOVAL AND INSTALLATION Removal And Installation Required Special - MD998770: Oxygen Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 2712 Use special tool MD998770 to remove the oxygen sensor. INSTALLATION SERVICE POINT >>A<< RIGHT BANK HEATED OXYGEN SENSOR (FRONT)/RIGHT BANK HEATED OXYGEN SENSOR (REAR)/LEFT BANK HEATED OXYGEN SENSOR (REAR)/HEATED OXYGEN SENSOR (REAR) INSTALLATION Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2719 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2720 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2721 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2722 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2723 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations View D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2727 Vehicle Speed Sensor: Testing and Inspection VEHICLE SPEED SENSOR CHECK 1. Remove the vehicle speed sensor and connect a 3-10 kilo ohm resistor as shown in the illustration. 2. Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2 - 3. (1 turn = 4 pulses) 3. If within the standard value, the vehicle speed sensor is OK. If not within the standard value, replace the vehicle speed sensor. Standard value: Voltage alternates between 0 volt and 5 volts four times per turn. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2728 Vehicle Speed Sensor: Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2729 Disassembly And Assembly Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2733 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2734 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2735 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2736 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2737 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations View D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2741 Vehicle Speed Sensor: Testing and Inspection VEHICLE SPEED SENSOR CHECK 1. Remove the vehicle speed sensor and connect a 3-10 kilo ohm resistor as shown in the illustration. 2. Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2 - 3. (1 turn = 4 pulses) 3. If within the standard value, the vehicle speed sensor is OK. If not within the standard value, replace the vehicle speed sensor. Standard value: Voltage alternates between 0 volt and 5 volts four times per turn. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2742 Vehicle Speed Sensor: Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2743 Disassembly And Assembly Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Diagrams Catalytic Converter: Diagrams EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER <2.4L> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Diagrams > Page 2748 Catalytic Converter: Description and Operation The three-way catalytic converter, together with the closed loop air-fuel ratio control based on the oxygen sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC) and reduces nitrogen oxides (NOx). When the mixture is controlied at stoichiometric air-fuel ratio, the three-way catalytic converter provides the highest purIfication against the three constituents, namely, CO, HC and NOx. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Diagrams > Page 2749 Catalytic Converter: Service and Repair REMOVAL AND INSTALLATION Removal And Installation Required Special - MD998770: Oxygen Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Diagrams > Page 2750 Use special tool MD998770 to remove the oxygen sensor. INSTALLATION SERVICE POINT >>A<< RIGHT BANK HEATED OXYGEN SENSOR (FRONT)/RIGHT BANK HEATED OXYGEN SENSOR (REAR)/LEFT BANK HEATED OXYGEN SENSOR (REAR)/HEATED OXYGEN SENSOR (REAR) INSTALLATION Use special tool MD998770 to installation the oxygen sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2755 Canister Purge Solenoid: Testing and Inspection EVAPORATIVE EMISSION PURGE SOLENOID CHECK 1. Remove the air intake hose <2.4L ENGINE>. 2. Disconnect the vacuum hose (black, black with red paint mark) from the EVAP purge solenoid. NOTE: When disconnecting the vacuum hose, always place an identification mark so that it can be reconnected at its odginal position. 3. Disconnect the harness connector. 4. Connect a hand vacuum pump to nipple (A) of the EVAP purge solenoid (refer to the illustration at left). 5. As described in the chart below, check airtightness by applying a vacuum with voltage applied directly from the battery to the EVAP purge solenoid valve and without applying voltage. 6. Measure the resistance between the terminals of the EVAP purge solenoid. Standard value: 30 - 34 Ohm @ 20 °C (68 °F) 7. Replace solenoid if resistance is out of specification. CHAMBER CHECK <2.4L ENGINE> Remove the vacuum hose and chamber assembly, and check that the assembly is not cogged by blowing it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Testing and Inspection Canister Vent Valve: Testing and Inspection Removal and Installation INSPECTION OVER VENT VALVE MODULE CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Testing and Inspection > Page 2760 1. Blow air through over vent valve module nipple (A). Check that the air flows out of nipple (B) and nipple (C). 2. Connect a hand vacuum pump to nipple (A) of the over vent valve module. 3. With air flow through nipple (C) obstructed, apply a vacuum and check that the vacuum is maintained. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Testing and Inspection > Page 2761 4. Check air tightness by applying a vacuum with voltage applied directly from the battery to the over vent valve module and without applying voltage. BATTERY VOLTAGENORMAL CONDITION Applied Vacuum maintained Not applied Vacuum leaks 5. Measure the resistance between the terminals of the solenoid. Standard value: 17 - 21 ohms @ 20 °C (68 °F) 6. Replace over vent valve module if resistance is out of specification. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Locations Leak Detection Solenoid: Locations Overall View View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations EGR Control Solenoid: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 2769 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 2770 EGR Control Solenoid: Testing and Inspection 1. Disconnect the vacuum hose from the EGR solenoid. NOTE: When disconnecting the vacuum hose, always make sure that it can be reconnected at its original position. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the EGR solenoid. (Refer to the illustration at left.) 4. As described in the chart below, check airtightness by applying a vacuum with voltage applied directly from the battery to the EGR solenoid and without applying voltage. BATTERY POSITIVE VOLTAGENORMAL CONDITION Not applied Vacuum leaks Applied Vacuum maintained 5. Measure the resistance between the terminals of the EGR solenoid Standard value: 29 - 35 ohms @ 20 °C (68 °F) 6. Replace the solenoid if resistance is out of specification. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 2774 EGR Valve: Testing and Inspection 1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly. 2. Connect a hand vacuum pump to the EGR valve. 3. Apply 67 kPa (20 in Hg) of vacuum, and check to be sure that the vacuum is maintained. 4. As described in the chart below, apply a vacuum and check the passage of air by blowing through one side of the EGR passage. VACUUM PASSAGE OF AIR 5.3 kPa (1.6 in Hg) or less Air is not blown out 29 kPa (8.7 in Hg) or more Air is blown out NOTE: Passage of air should be checked by blowing the valve port. 5. Reinstall the EGR valve, using a new gasket, and tighten to the specified torque. Tightening torque: <2.4L ENGINE> .............................................................................................................................................................. 19 ± 3 Nm (14 ± 2 ft. lbs.) <3.0L ENGINE> .............................................................................................................................................................. 22 ± 4 Nm (16 ± 3 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2779 Positive Crankcase Ventilation Valve: Testing and Inspection 1. Hold the PCV valve with the vacuum side down. Insert a thin rod, and using light pressure, depress the end of the PCV valve spring by 5 - 10 mm (0.2 - 0.3 inch). Release pressure on the rod to see if the PCV valve spring will lift the rod to its original position. 2. If the rod returns quickly to its original position, the PCV valve is OK. If the stick does not return quickly. clean or replace the PCV valve. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure kPa (psi) Vacuum hose disconnected ................................................................................................................................................... 330 350 (47 - 50) at curb idle Vacuum hose connected ............................................................................................................................................... Approximately 270 (38) at curb idle Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2784 Fuel Pressure: Testing and Inspection FUEL PRESSURE TEST Required Special Tools: - MB9915Q2: Scan Tool (MUT-II) - MB991637: Fuel Pressure Gauge Set - MD998709: Adaptor Hose - MD998742: Hose Adaptor 1. Release residual pressure from the fuel line to prevent fuel spray. WARNING To prevent a fire, cover the hose connection with shop towels to prevent splashing of fuel that could be caused by Some residual pressure in the fuel pipe line. 2. Disconnect the high-pressure fuel hose at the fuel rail side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2785 3. Assemble the fuel pressure measurement tools as follows. 1. Rempve the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Place a suitable O-ring or gasket on assembled special tools MD998709 and MD998742 and install the fuel pressure gauge. 3. Install the assembled fuel pressure measurement tools between the fuel rail and high-pressure fuel hose. 1. Remove the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Install special tool MB991637 (fuel pressure gauge set) to assembled special tools MD998709 and MD998742 via a gasket. 3. Install the assembled fuel pressure measurement tools between the fuel rail and the high-pressure fuel hose. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 4. Connect scan tool MB991502 to the data link connector. 5. Use the Actuator test 07 to drive the fuel pump. Check that there is no fuel leaking from any section when the fuel pump is operating. 6. Stop the fuel pump. 7. Start the engine and run at idle. 8. Measure fuel pressure while the engine is running at idle. Standard value: Approximately 270 kPa (38 psi) at curb idle 9. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed with your finger. Standard value: 330 - 350 kPa (47 - 50 psi) at curb idle 10. Check to see that fuel pressure at idle does not drop even after the engine has been revved several times. 11. Revving the engine repeatedly, hold the fuel return hose lightly with your fingers to feel that fuel pressure is present in the return hose. NOTE:If the fuel flow rate is low, there will be no fuel pressure in the return hose. 12. If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2786 13. Stop the engine and observe fuel pressure gauge reading. It is normal if the reading does not drop within two minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Start, then stop the engine. 1. Squeeze the fuel return line closed to confirm leak-down occurs from defective fuel pressure regulator. 2. Squeeze the fuel supply line closed to confirm leak-down occurs from defective fuel pump check valve. 3. If pressure continues to drop with both fuel lines squeezed closed, injector(s) are leaking. 14. Release residual pressure from the fuel pipe line. WARNING Cover the hose connection with shop towels to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. 15. Remove the fuel pressure gauge, and special tools MD998709 and MD998742 from the fuel rail. 16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. 17. Fit the high-pressure fuel hose into the fuel rail and tighten the bolts to specified torque. Tightening torque: 4.9 ± 1.0 (44 ± 8 in. lbs.) 18. Check for fuel leaks. 1. Use scan tool MB991502 to operate the fuel pump. 2. Check the fuel tine for leaks, and repair as needed. 19. Disconnect scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 2790 Fuel Pressure Release: Service and Repair FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the instrument panel side cover (driver's side). 2. Disconnect the fuel pump relay (2). 3. Start the engine and let it run until it stops naturally. Turn the ignition switch to the "LOCK" (OFF) position. 4. Connect the fuel pump relay (2). 5. Install the instrument panel side cover (driver's side). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Basic idle speed .................................................................................................................................. .............................................................. 700 ± 50 rpm Curd idle speed .............................................. ................................................................................................................................................. 700 ± 100 rpm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2794 Idle Speed: Testing and Inspection CURB IDLE SPEED CHECK Required Special Tool: ^ MB991502: Scan Tool (MUT-II) 1. Before inspection and adjustment set vehicles in the following condition. ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB99150 2. 2. Connect scan tool MB991502 to the data link connector. 3. Check the basic ignition timing. Standard value: 5 ± 3 °BTDC 4. Start the engine. 5 Run the engine at idle for 2 minutes. 6. Check the idle speed. Select item number 22 and take a reading of the idle speed. Curb idle speed: 700 ± 100 rpm NOTE: The idle speed is controlled automatically by the idle air control system. 7. If the idle speed is outside the standard value, refer to Multiport Fuel Injection (MFI) Diagnosis Symptom Chart. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2795 Idle Speed: Adjustments BASIC IDLE SPEED ADJUSTMENT Required Special Tool: - MB991502: Scan Tool (MUT-II) NOTE: The standard idle speed has been adjusted with the speed adjusting screw (SAS), by the manufacturer, and there should be no need for readjustment. NOTE: If the adjustment has been changed by mistake, the idle speed may become too high Qr the idle speed may drop too low when loads A/C, defogger, etc. are placed on the engine. If this occurs, adjust by the following procedure. NOTE: The adjustment; if made, should be made after first confirming that the spark plugs, the injectors, the idle air control motor, compression, etc., are all normal. 1. The vehicle should be prepared as follows before the inspection and adjustment. - Engine coolant temperature: 80 - 95 °C (176 - 203 °F) - Lights, electric cooling fan and accessories: OFF - Transaxie: Neutral (A/T for "P" range) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting Qr disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector (16-pin). 3. Start the engine and run at idle. 4. Select the item number 30 of the scan tool Actuator test. NOTE: Use the scan tool to hold the IAC motor at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 700 ± 50 rpm NOTE: The engine speed may be 20 to 100 rpm lower than indicated above for a new vehicle [driven approximately 500 km (300 mile) or less, but no adjustment is necessary. If the engine stalls or the engine speed is low even though the vehicle has been driyen approximately 500 km (300 mile) or more, it is probable that deposits are adhered to the throttle valve, so clean it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 2796 6. If not withih the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment. 7. Press the recan tool clear key, and release the IAC motor Actuator test mode. 8. Turn the ignition switch to the "LOCK" (OFF) position. NOTE: Unless the IAC motor is released, the Actuator Test Mode will continue for 27 minutes. 9. Disconnect scan tool MB991502. 10. Start the engine again and let it idle for about 10 minutes. Check that the idling condition is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > System Diagnosis Air/Fuel Mixture: Testing and Inspection IDLE MIXTURE CHECK Required Special Tool: MB991502: Scan Tool (MUT-II) 1. Before inspection, set vehicles in the following condition: ^ Engine coolant temperature: 80 - 95 °C (176 - 203 °F) ^ Lights and all accessories: OFF ^ Transaxle: Neutral (P range on vehicles with A/T) CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 2. Connect scan tool MB991502 to the data link connector: 3. Check that the basic ignition timing is within the standard value. Standard value: 5 ± 3 °BTDC 4. Start the engine and increase the engine speed to 2,500 rpm for 2 minutes. 5 Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value: CO contents: 0.5 % or less HC contents: 100 ppm or less 7. If the CO and HC contents do not remain inside the standard value; check the following items: NOTE: Replace the catalytic converter when the CO and HC contents do not remain inside the standard value, even though the result of the inspection is normal for all items. ^ Diagnosis output ^ Closed-loop control (When the closed-loop control is carried out normally, the output signal of the heated oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) ^ Fuel pressures ^ Injector ^ Ignition coil, spark plug cable, spark plug ^ EGR system and EGR valve leak ^ Evaporative emission control system ^ Compression pressure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Fastener Tightening Specifications Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2803 Accelerator Pedal: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 2804 Accelerator Pedal: Description and Operation GENERAL DESCRIPTION A cable-type accelerator mechanism and a suspended-type pedal have been adopted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview ENGINE CONTROL SYSTEM DIAGNOSIS INTRODUCTION If there is a malfunction in the engine control system, the accelerator cable, accelerator pedal or throttle lever may be faulty. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2807 Accelerator Pedal: Symptom Related Diagnostic Procedures Troubleshooting Strategy TROUBLESHOOTING STRATEGY Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find an engine control system fault. 1. Gather information from the customer. 2. Verify that the condition described by the customer exists. 3. Find the malfunction by following the Symptom Chart. 4. Verify malfunction is eliminated. Symptom Chart Inspection Procedure 1 INSPECTION PROCEDURE 1: Throttle Valve will not Fully Open or Close DIAGNOSIS STEP 1. Check the accelerator cable adjustment. Q: Is the accelerator cable properly adjusted? YES: Go to Step 2. NO: Adjust the accelerator cable. Then go to Step 4. STEP 2. Check the return spring. Q: Is the return spring damaged or deformed? YES: Go to Step 3. NO: Replace, then go to Step 4. STEP 3. Check the throttle lever. Q: Is the throttle lever damaged or deformed? YES: Replace, then go to Step 4. NO: There is no action to be taken. STEP 4. Check symptom. Q: Does the throttle valve fully open and close? YES: The procedure is complete. NO: Return to Step 1. Inspection Procedure 2 INSPECTION PROCEDURE 2: Accelerator Pedal Operation not Smooth (Over Acceleration) DIAGNOSIS STEP 1. Check the accelerator pedal. Q: Is the accelerator pedal loose? YES: Tighten, then go to Step 4. NO: Go to Step 2. STEP 2. Check the accelerator cable wiring. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2808 Q: Is the accelerator cable routing bent sharply? YES: Repair, then go to Step 4. NO: Go to Step 3. STEP 3. Check the accelerator cable lubricant. Q: Is the accelerator cable lubricated sufficiently? YES: There is no action to be taken. NO: Refill or replace the lubricant, then go to Step 4. STEP 4. Check symptom. Q: Does the accelerator pedal work normally? YES: The procedure is complete. NO: Return to Step 1. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Specifications Air Cleaner Housing: Specifications Air cleaner bolt ..................................................................................................................................... ................................... 8.8 ± 1.0 Nm (78 ± 9 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Specifications > Page 2812 Air Cleaner Housing: Diagrams AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Specifications > Page 2813 Air Cleaner Housing: Service and Repair AIR CLEANER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2817 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2818 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Capacity Specifications Fuel: Capacity Specifications Fuel Tank Capacity Fuel Tank Capacity 16.4 gal (62 dm3) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Capacity Specifications > Page 2823 Fuel: Fluid Type Specifications Minimum Octane Rating ...................................................................................................................... .................................................................. 87 octane Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 °C (1000 °F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - Over tightening the pump lock ring may result in a leak. - The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2828 Fuel Pressure Release: Service and Repair FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINES) WARNING When removing the fuel pipe, etc., release fuel pressure to prevent fuel spray. 1. Remove the instrument panel side cover (driver's side). 2. Disconnect the fuel pump relay (2). 3. Start the engine and let it run until it stops naturally. Turn the ignition switch to the "LOCK" (OFF) position. 4. Connect the fuel pump relay (2). 5. Install the instrument panel side cover (driver's side). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Injector coil resistance ........................................................................................................................................................... 13 - 16 ohms @ 20 °C (68 °F) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Oscilloscope Test Fuel Injector: Testing and Inspection Oscilloscope Test INJECTOR Required Special Tool: - MD991348: Test Harness Set Measurement Method 1. Disconnect the injector connector and connect the test harness special tool MB991348 in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to injector connector terminal No.2. Alternate method (Test harness not available) 1. Connect the oscilloscope probe to ECM terminal No.1. (When checking the number 1 cylinder.) 2. Connect the oscilloscope probe to ECM terminal No.14. (When checking the number 2 cylinder.) 3. Connect the oscilloscope probe to ECM terminal No.2. (When checking the number 3 cylinder.) 4. Connect the oscilloscope probe to ECM terminal No.15. (When checking the number 4 cylinder.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Oscilloscope Test > Page 2834 Standard Wave Pattern Wave Pattern Observation Points 1. Connect the oscilloscope probe to PCM terminal No.1. (When checking the number 1 cylinder.) 2. Connect the oscilloscope probe to PCM terminal No.9 (When checking the number 2 cylinder) 3. Connect the oscilloscope probe to PCM terminal No. 24 (When checking the number 3 cylinder.) 4. Connect the oscilloscope probe to PCM terminal No.2 (When checking the number 4 cylinder.) Wave Pattern Observation Points Point A: Height of injector coil induced voltage. Point B: Injector drive time. 1. The injector drive time should be synchronized with the scan tool tester display. 2. When the engine is suddenly revved, the drive time will be greatly extended at first, but the drive time will soon return to original length. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Oscilloscope Test > Page 2835 Fuel Injector: Testing and Inspection Resistance Test INJECTOR CHECK Measurement of Resistance between Terminals 1. Disconnect the injector intermediate connector. 2. Measure resistance between terminals. Standard value: 13 - 16 Ohm @ 20 °C (68 °F) 3. If not within specification, replace the injector. 4. Install the injector connector Checking operation sound Using a steth6scope or long blade screwdriver, check the operation sound ("tick-tick-tick") of injectors during idling or during cranking. Check that as the engine speed increases, the frequency of the operating sound also increases. 1. If the injector you are checking is not operating, you may hear the operating sound of the other injectors. 2. If no operating sound is heard from the injector that is being checked, check the injector drive circuit. If there is nothing wrong with the circuit, a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 2836 Fuel Injector: Service and Repair INJECTOR REMOVAL AND INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 2837 3. If it dose not turn smoothly, the O-ring may be trapped, remove the item, re-install it into the fuel rail and check again. 4. Tighten the fuel pressure regulator and high-pressure fuel hose to the specified torque. Tightening torque: 8.8 Nm (78 in. lbs.) 4.9 Nm (44 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair Fuel Pressure Regulator: Service and Repair INJECTOR REMOVAL AND INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Page 2841 3. If it dose not turn smoothly, the O-ring may be trapped, remove the item, re-install it into the fuel rail and check again. 4. Tighten the fuel pressure regulator and high-pressure fuel hose to the specified torque. Tightening torque: 8.8 Nm (78 in. lbs.) 4.9 Nm (44 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel pressure kPa (psi) Vacuum hose disconnected ................................................................................................................................................... 330 350 (47 - 50) at curb idle Vacuum hose connected ............................................................................................................................................... Approximately 270 (38) at curb idle Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2846 Fuel Pressure: Testing and Inspection FUEL PRESSURE TEST Required Special Tools: - MB9915Q2: Scan Tool (MUT-II) - MB991637: Fuel Pressure Gauge Set - MD998709: Adaptor Hose - MD998742: Hose Adaptor 1. Release residual pressure from the fuel line to prevent fuel spray. WARNING To prevent a fire, cover the hose connection with shop towels to prevent splashing of fuel that could be caused by Some residual pressure in the fuel pipe line. 2. Disconnect the high-pressure fuel hose at the fuel rail side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2847 3. Assemble the fuel pressure measurement tools as follows. 1. Rempve the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Place a suitable O-ring or gasket on assembled special tools MD998709 and MD998742 and install the fuel pressure gauge. 3. Install the assembled fuel pressure measurement tools between the fuel rail and high-pressure fuel hose. 1. Remove the union joint and bolt from special tool MD998709 (adaptor hose) and instead attach special tool MD998742 (hose adaptor) to the adaptor hose. 2. Install special tool MB991637 (fuel pressure gauge set) to assembled special tools MD998709 and MD998742 via a gasket. 3. Install the assembled fuel pressure measurement tools between the fuel rail and the high-pressure fuel hose. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 4. Connect scan tool MB991502 to the data link connector. 5. Use the Actuator test 07 to drive the fuel pump. Check that there is no fuel leaking from any section when the fuel pump is operating. 6. Stop the fuel pump. 7. Start the engine and run at idle. 8. Measure fuel pressure while the engine is running at idle. Standard value: Approximately 270 kPa (38 psi) at curb idle 9. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed with your finger. Standard value: 330 - 350 kPa (47 - 50 psi) at curb idle 10. Check to see that fuel pressure at idle does not drop even after the engine has been revved several times. 11. Revving the engine repeatedly, hold the fuel return hose lightly with your fingers to feel that fuel pressure is present in the return hose. NOTE:If the fuel flow rate is low, there will be no fuel pressure in the return hose. 12. If any of fuel pressure measured in steps 10 to 13 is out of specification, troubleshoot and repair according to the table below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2848 13. Stop the engine and observe fuel pressure gauge reading. It is normal if the reading does not drop within two minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below. Start, then stop the engine. 1. Squeeze the fuel return line closed to confirm leak-down occurs from defective fuel pressure regulator. 2. Squeeze the fuel supply line closed to confirm leak-down occurs from defective fuel pump check valve. 3. If pressure continues to drop with both fuel lines squeezed closed, injector(s) are leaking. 14. Release residual pressure from the fuel pipe line. WARNING Cover the hose connection with shop towels to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. 15. Remove the fuel pressure gauge, and special tools MD998709 and MD998742 from the fuel rail. 16. Replace the O-ring at the end of the high-pressure fuel hose with a new one. 17. Fit the high-pressure fuel hose into the fuel rail and tighten the bolts to specified torque. Tightening torque: 4.9 ± 1.0 (44 ± 8 in. lbs.) 18. Check for fuel leaks. 1. Use scan tool MB991502 to operate the fuel pump. 2. Check the fuel tine for leaks, and repair as needed. 19. Disconnect scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 2852 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay Continuity Check FUEL PUMP RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair Fuel Rail: Service and Repair INJECTOR REMOVAL AND INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Page 2856 3. If it dose not turn smoothly, the O-ring may be trapped, remove the item, re-install it into the fuel rail and check again. 4. Tighten the fuel pressure regulator and high-pressure fuel hose to the specified torque. Tightening torque: 8.8 Nm (78 in. lbs.) 4.9 Nm (44 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Fuel Gauge Sender: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Check FUEL GAUGE UNIT CHECK Remove the fuel pump module and the remove the fuel gauge unit. (Refer to Fuel Tank.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 2885 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Resistance FUEL GAUGE UNIT RESISTANCE 1. Check that resistance value between the fuel gauge terminal and ground terminal is at the standard value when the fuel gauge unit float is between point Standard value: Point F: 3-5 ohms - Point E: 110 - 112 ohms 2. Check that resistance value changes smoothly when the float moves slowly between point 3. If no problems are found in steps above, go to Fuel gauge unit float height check. If any problem is found, replace the fuel gauge unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 2886 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Float Height FUEL GAUGE UNIT FLOAT HEIGHT 1. Move the float and measure height A at point Standard value: A: 180.3 mm (7.10 inches) - B: 18.8 mm (0.14 inch) 2. Adjust the float arm to the standard value, then go to Thermistor check. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Fuel Tank Unit: Locations View a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 2890 Fuel Tank Unit: Service and Repair ON-VEHICLE SERVICE FUEL PUMP MODULE REPLACEMENT 1. Remove the rear seat cushion. (Refer to Rear Seat) 2. Remove the protector. 3. Bleed the residual pressure from inside the fuel pipe line to prevent the fuel from spraying out. [Refer to On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Line) <2.4L ENGINE> [Refer to On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Line.) <3.0L ENGINE> 4. Disconnect the hose and connector connections, and then use special tool MB991480 to remove the fuel pump module. CAUTION Install the packing to the fuel tank, and then install the fuel pump module to the fuel tank. Installing the packing to the fuel pump module will damage the packing lip when installing the fuel pump module to the fuel tank, and fuel leakage will occur. 5. Check that the fuel tank is notdamaged or deformed, and then securely install the parking to the fuel tank. NOTE: If the packing is damaged or deformed, replace with new packing. CAUTION Do not tilt the fuel pump module when installing. - The packing should not be folded over as shown by "A" in the illustration. 6. Apply soap water to the inside of the packing, and then install the fuel pump module. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 2891 CAUTION When Tightening, be careful not to let the fuel pump module turn together with the cap. If the mating marks are misaligned, the float may measure a remaining amount of fuel in correctly, causing the low fuel warning light to malfunction 7. Use special tool MB991480 to align the mating marks on the fuel tank and fuel pump module, and tighten the cap to the specified torque. Tightening torque: 80 ± 10 Nm (59 ± 7 ft-lb) 8. Check for leaks from the installation section of the fuel pump module by the following procedure. 1. Apply soapy water to the inside diameter of the cap. 2. Choke the vapor hose and main hose, apply an internal pressure of 10 kPa (1.45 psi) or less from the return hose and check that no bubbles form in the soapy water. 9. Connect the connector, and then install the protector. 10. Install the rear seat cushion. (Refer to Rear Seat.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control (IAC) Motor: Specifications Idle Air Control Motor Coil Resistance ................................................................................................................................. 28 - 33 ohms @ 20 °C (68 °F) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2895 Idle Air Control (IAC) Motor: Locations Overall View View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test Idle Air Control (IAC) Motor: Testing and Inspection Oscilloscope Test IDLE AIR CONTROL MOTOR (STEPPER MOTOR) Required Special Tool: - MB991709: Test Harness Set Measurement Method 1. Disconnect the idle air control motor connector, and connect the test harness special tool, MB991709 in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the idle air control motor connector terminal No.1, terminal No.3, terminal No.4 and terminal No.6, respectively. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2898 Wave Pattern Observation Points Check that the standard wave pattern appears when the idle air control motor is operating. PointA: Wave Pattern Observation Points Presence or absence of induced electromotive force from the motor turning. (Refer to abnormal wave pattern.) Point B: Wave Pattern Observation Points Height of coil back electromotive force Examples of Abnormal Wave Patterns Example 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2899 - Cause of problem Malfunction of motor. (Motor is not operating.) - Wave pattern characteristics Induced electromotive force from the motor turning does not appear. Example 2 - Cause of problem Open circuit in the line between the idle air control motor and the ECM or PCM. - Wave pattern characteristics Current is not supplied to the motor coil on the open circuit side. (Voltage does not drop to 0 volt.) Furthermore, the induced electromotive force wave pattern at the normal side is slightly different from the normalwave pattern. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2900 Idle Air Control (IAC) Motor: Testing and Inspection Resistance Test IDLE AIR CONTROL MOTOR (STEPPER MOTOR) CHECK Required Special Tool: - MB991709: Test Harness Set Checking the Operation Sound 1. Check that the engine coolant temperature is 20 °C (68 °F) or below. NOTE: If necessary you can disconnect the engine coolant temperature sensor connector and connect the harness-side of the connector to another engine coolant temperature sensor that is at 20 °C (68 °F) or below. 2. Check that the operation sound of the stepper motor can be heard after the ignition is switched ON (but do not start the engine). 3. If the operation sound cannot be heard, check the stepper motor's activation circuit. If the circuit is normal, it is probable that there is a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Motor <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Testing and Inspection > Oscilloscope Test > Page 2901 2. Measure resistance between terminal No. 2 and either terminal No. 1 or terminal No. 3 of the connector at the idle air control motor side. Standard value: 28 - 33 ohms @ 20 °C (68 °F) 3. If resistance is not within the standard value, replace the IAC motor. 4. Measure the resistance between terminal No. 5 and either terminal No. 6 or terminal No. 4 of the connector at the idle air control motor side. Standard value: 28 - 33 ohms @ 20 °C (68 °F) 5. If resistance is not within the standard value, replace the IAC motor 1. Remove the throttle body. 2. Remove the idle air control motor. 3. Connect special tool MB991709 to the idle air control motor connector. 4. Connect the positive (+) terminal of a power supply (approximately 6 volts) to terminal No. 2 and the terminal No. 5. 5. Connect the negative (-) terminal of the power supply to each clip as described in the following steps. Then check whether or not the stepper motor vibrates slightly as it operates. 1. Connect the negative terminal of the power supply to terminal No. 1 and terminal No. 4. 2. Connect the negative terminal of the power supply to terminal No. 3 and terminal No. 4. 3. Connect the negative terminal of the power supply to terminal No. 3 and terminal No. 6. 4. Connect the negative terminal of the power supply to terminal No. 1 and terminal No. 6. 5. Connect the negative terminal of the power supply to terminal No. 1 and terminal No. 4. 6. Repeat the tests in sequence from (5) to (1) to test opposite movement of the IAC. 6. If vibration is detected during the test, the stepper motor can be considered to be normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2905 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil pressure switch .............................................................................................................................. ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2913 Fuel Pump Relay: Testing and Inspection Fuel Pump Relay Continuity Check FUEL PUMP RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2917 Main Relay (Computer/Fuel System): Testing and Inspection Multiport Fuel Injection (MFI) Relay Continuity Check MULTIPORT FUEL INJECTION (MFI) RELAY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations View N Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2922 Air Flow Meter/Sensor: Testing and Inspection INSPECTION PROCEDURE USING AN OSCILLOSCOPE VOLUME AIR FLOW SENSOR Required Special Tool: - MB91709: Test Harness Set Measurement Method 1. Disconnect the volume air flow sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to volume air flow sensor connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2923 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased. Examples of Abnormal Wave Patterns Example 1 Cause of problem - Sensor interface malfunction. Wave pattern characteristics - Rectangular wave pattern is output even when the engine is not started. Example 2 Cause of problem - Damaged rectifier or vortex generation column. Wave pattern characteristics - Unstable wave pattern with non-uniform frequency. An ignition leak will distort the wave pattern temporarily, even if the volume air flow sensor is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Specifications Oil Pressure Switch (For Fuel Pump): Specifications Oil pressure switch .............................................................................................................................. ......................................... 19 ± 3 Nm (14 ± 2 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2930 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2931 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2932 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2933 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2934 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning Throttle Body: Service and Repair Throttle Body Cleaning THROTTLE BODY (THROTTLE VALVE AREA) CLEANING 1. Start the engine and warm it up until the coolant is heated to 80 °C (176 °F) or higher. Then stop the engine. 2. Remove the air intake hose from the throttle body. CAUTION Do not allow cleaning solvent to enter the bypass passage. 3. Plug the bypass passage inlet (arrow) of the throttle body. 4. Spray cleaning solvent into the valve through the throttle body intake port and leave it for approximately five minutes. 5. Start the engine, rev it several times and then idle it for about one minute. If the idling speed becomes unstable (or if the engine stalls) due to the bypass passage being plugged, slightly open the throttle valve to keep the engine running. 6. If the throttle valve deposits are not removed, repeat steps 4 and 5. 7. Unplug the bypass passage inlet. 8. Attach the air intake hose. 9. Use the scan tool to erase any diagnostic trouble code. 10. Adjust the basic idle speed. WARNING Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. NOTE: If the engine hunts while idling after adjustment of the basic idle speed, disconnect the negative cable from the battery for 10 seconds or more, and then reconnect it and run the engine at idle for about 10 minutes after the engine is warmed up. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 2939 Throttle Body: Service and Repair Removal and Installation INSTALLATION SERVICE POINT Throttle Body Assembly >>A< CAUTION: Poor idling etc. may result if the throttle body gasket is installed incorrectly. Install the throttle body gasket as shown in the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 2940 Throttle Body: Service and Repair Disassembly and Assembly DISASSEMBLY SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 2941 1. Install the throttle position sensor to the throttle body as shown in the illustration. 2. Turn the throttle position sensor 90 degrees counterclockwise to set it, and tighten the screws. 3. Connect an ohmmeter between terminals 1 (ground) and 3 (output), or between terminals 3 (output) and 4 (power). Then, make sure that the resistance changes smoothly when the throttle valve is slowly moved to the fully open position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Adjustments Throttle Cable/Linkage: Adjustments ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT 1. Turn A/C and lamps OFF. Inspect and adjust at no load. 2. Warm engine until stabilized at idle. 3. Confirm idle speed is at standard value. Standard value: 700 ± 100 rpm 4. Stop engine. [ignition switch: "LOCK" (OFF) position. 5. Confirm there are no sharp bends in the accelerator cable. 6. Check the inner cable for correct slack. Standard value: 1.0 - 2.0 mm (0.04 - 0.08 in.) 7. If there is too much slack or no slack, adjust play by the following procedures. 1. Loosen the adjusting bolt to release the cable. 2. Move the plate until the inner cable play is at the standard value, and then tighten the adjusting bolt. 3. After adjusting, check that the throttle lever is touching the stopper Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Adjustments > Page 2945 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle position sensor adjusting voltage mV ....................................................................................................................................................... 535 - 735 Throttle position sensor resistance kOhm .................................................................................. ............................................................................... 3.5 - 6.5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2949 Throttle Position Sensor: Locations View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2950 Throttle Position Sensor: Testing and Inspection THROTTLE POSITION SENSOR CHECK Required Special Tool: - MB991348: Test Harness Set Checking the Terminal Resistance 1. Disconnect the throttle position sensor connector. 2. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.4. Standard value: 3.5 - 6.5 kOhm 3. Measure resistance between the throttle position sensor side connector terminal No.1 and terminal No.3. Normal condition: Throttle valve slowly open until Changes smoothly in proportion to the fully open from the idle position opening angle of throttle valve 4. If resistance is outside the standard value, or if it doesn't change smoothly, replace the throttle position sensor. NOTE: After replacement the throttle position sensor should be adjusted. Check using oscilloscope 1. Disconnect the throttle position sensor connector and connect the test harness special too (MB991348) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to the throttle position sensor side connector terminal No. 3. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2951 3. Turn the ignition switch "ON" position. 4. Slowly move the throttle lever from the idle position to the full-throttle position and check then if the waveform is free from any noise. 5. If any noise is recognised, replace the throttle position sensor. NOTE: After replacement, the throttle position sensor should be adjusted. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2952 Throttle Position Sensor: Adjustments THROTTLE POSITION SENSOR ADJUSTMENT Required Special Tools: - MB991502: Scan Tool (MUT-II) - MB991348: Test Harness Set CAUTION To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting the scan tool MB991502. 1. Connect scan tool MB991502 to the data link connector. When not using scan tool follow the steps below. 1. Disconnect the throttle position sensor connector, and connect the special tool MB991348 in between. (All terminals should be connected.) 2. Connect a digital voltmeter between throttle position sensor terminal No.3 (sensor output) and terminal No.1 (sensor ground). 2. Turn the ignition switch to the "ON" position (but do not start the engine). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2953 3. Check the throttle position sensor output voltage. Standard value: 535 - 735 mV 4. If not within the standard value range, adjust by loosening throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to the "LOCK" (OFF) position. 6. Disconnect scan tool MB991502. When the scan tool is not used, remove special tool MB991348, and connect the throttle position sensor connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications DESCRIPTION - 2.4L ENGINE The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft with hydraulic lifters and four valve per cylinder design. The engine is free-wheeling; meaning it has provisions for piston-to-valve clearance. However valve-to-valve interference can occur, if camshafts are rotated independently. cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2959 Firing Order: Mechanical Specifications Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order 1-3-4-2 .............................................................................................................................................................. ............................................... Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2967 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2968 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2969 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2970 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2983 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2984 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2985 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2986 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2987 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2988 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2989 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2991 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2992 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2993 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2994 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2995 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2997 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2998 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2999 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 3000 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection Measure the resistance of the all spark plug leads. 1. Check the cap and coating for cracks. 2. Measure the resistance. Limit: 19 kilo ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions Ignition Coil: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 Ignition Coil: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3027 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3028 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3029 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3030 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3031 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Check Ignition Coil: Testing and Inspection Ignition Coil Check IGNITION COIL CHECK <2.4L ENGINE - With built-in ignition power transistor> Check by the following procedure, and replace the coil if there is a malfunction. SECONDARY COIL RESISTANCE CHECK Measure the resistance between the high-voltage terminals of the ignition coil. Standard value: 8.5 - 11.5 kilo ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Check > Page 3034 Ignition Coil: Testing and Inspection Primary Coil and Ignition Power Transistor Continuity Check NOTE: An analog-type ohmmeter should be used. NOTE: Connect the negative probe of the ohmmeter to terminal 1. CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent coil from burning and ignition power transistor from breaking. As described in the chart below, perform a continuity check on the ignition coil power transistor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Check > Page 3035 Ignition Coil: Testing and Inspection Oscilloscope Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method Standard Wave Pattern 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Check > Page 3036 Connect the oscilloscope probe to ECM terminal No.10 (for number 1 number 4), terminal No.23 (for number 2 - number 3) respectively. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Ignition Coil Check > Page 3037 Malfunction in ignition power transistor - Wave pattern characteristics Power voltage results when the ignition power transistor is ON. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3038 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 Ignition Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3062 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3063 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check Ignition Control Module: Testing and Inspection Analyser Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method Standard Wave Pattern 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 3066 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 3067 Ignition Control Module: Testing and Inspection Oscilloscope Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 3068 Connect the oscilloscope probe to ECM terminal No.10 (for number 1 number 4), terminal No.23 (for number 2 - number 3) respectively. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3074 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3075 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3076 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3077 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3078 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3079 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3080 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3081 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3082 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3083 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3084 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3085 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3086 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3087 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3088 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3089 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3090 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3091 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3092 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3093 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3094 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 3095 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 3096 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Ignition Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3115 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3116 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3118 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3119 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check Ignition Control Module: Testing and Inspection Analyser Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method Standard Wave Pattern 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 3125 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 3126 Ignition Control Module: Testing and Inspection Oscilloscope Check IGNITION COIL AND IGNITION POWER TRANSISTOR Required Special Tool: MB991348: Test Harness Set Measurement Method 1. Disconnect the ignition coil connector, and connect test harness special tool, MB991348, in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to ignition coil connector terminal No.3. Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Testing and Inspection > Analyser Check > Page 3127 Connect the oscilloscope probe to ECM terminal No.10 (for number 1 number 4), terminal No.23 (for number 2 - number 3) respectively. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Views H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3132 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3133 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3134 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3135 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Locations Crankshaft Position Sensor: Locations View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3141 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3142 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3143 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3144 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3145 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3148 Crankshaft Position Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3155 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3156 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3157 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3158 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3159 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3160 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 3162 Crankshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR Required Special Tools: - MB991709: Test Harness Set - MD998478: Test Harness Measurement Method 1. Disconnect the camshaft position sensor connector, and connect the test harness special tool (MB991709) in between. (All terminals should be connected.) 2. Connect the oscilloscope probe to camshaft position sensor connector terminal No.2. 3. Disconnect the crankshaft position sensor connector, and connect the test harness special tool (MD998478) in between. 4. Connect the oscilloscope probe to crankshaft position sensor connector terminal No.2 (black clip of special tool). Alternate method (Test harness not available) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 3163 Standard Wave Pattern 1. Connect the oscilloscope probe to ECM terminal No.88. (Check the camshaft position sensor signal wave pattern.) 2. Connect the oscilloscope probe to ECM terminal No.89. (Check the crankshaft position sensor signal wave pattern.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 3164 - Cause of problem Sensor interface malfunction. Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. Example 2 - Cause of problem Loose timing belt. Abnormality in sensor disc. Wave pattern characteristics Wave pattern is displaced to the left or right. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 3165 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 Knock Sensor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3182 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3183 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3184 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3185 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3186 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3187 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3188 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3189 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3190 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3191 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3192 Knock Sensor: Service and Repair CAUTION: Do not drop or hit the knock sensor against other components. Internal damage may result, and the knock sensor will need to be replaced. Removal And Installation Required Special Tool: MD998773: knock Sensor Wrench REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 3193 Use special tool MD998773 to removal the knock sensor. INSTALLATION SERVICE POINT >>A<< KNOCK SENSOR INSTALLATION Use special tool MD998773 to install the knock sensor. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Spark Plug Gap ................................................................................................................................... ................................ 0.039 - 0.043 in. (1.0 - 1.1 mm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 3198 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................... 18 +/- 4 ft-lb (25 +/- 4 Nm) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3199 Spark Plug: Testing and Inspection SPARK PLUG CHECK AND CLEANING <2.4L ENGINE> 1. Check that the plug is not burned, that the insulator plug is not damaged, and that the seizure state is good. 2. If cleaning is required due to carbon deposits, etc., clean using a plug cleaner or wire brush, etc. 3. Check the plug gap using a plug gap gauge, and adjust if not within the standard value. Standard value: 1.0 - 1.1mm (0.039 - 0.043 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection F4A42 - Automatic Transmission INSPECTION SHIFT SWITCH ASSEMBLY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Testing and Inspection Transmission Temperature Sensor/Switch: Testing and Inspection A/T FLUID TEMPERATURE SENSOR CONTINUITY CHECK 1. Remove the A/T fluid temperature sensor. 2. Measure the resistance between terminals No. 1 and No.2 of the A/T control solenoid valve assembly connector. Standard value: 3. If the A/T fluid temperature sensor resistance is not consistent with the fluid temperature, replace A/T fluid temperature sensor. NOTE: The N range indicator light on the combination meter flashes when the temperature reaches approximately 125°C (257°F) or higher, and then Stops flashing when the temperature drops below approximately 115°C (23-wF). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-032-05 > Aug > 05 > Engine Controls - MIL ON/Misfire DTC's Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/Misfire DTC's Set NUMBER: 18-032-05 GROUP: Vehicle Performance DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-028-02 DATED SEPTEMBER 16, 2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THIS SERVICE BULLETIN PROVIDES AN UPDATE TO CONFORM TO THE TechCONNECT FLASH PROCESS. SUBJECT: Flash: MIL Illumination - Misfire Diagnostic Trouble Codes (DTC's) P0300, P0301, P0302, P0303, P0304 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM). MODELS: 2002 - 2003 (ST) Sebring/Stratus Coupe NOTE: This information applies to vehicles equipped with a 2.4L engine (sales code EY7) and manual transaxle built prior to October 1, 2002 (MDH1001XX) or with an automatic transaxle built prior to September 1, 2002 (MDH0901XX). SYMPTOM/CONDITION: The Malfunction Indicator Lamp (MIL) may illuminate due to one or more of the DTC's shown. The DTC('s) may be intermittent and provide no symptoms other than MIL Illumination. DIAGNOSIS: Using the DRBIII(R) and CH8425 PCMCIA Diagnostic Card check for DTC's. If other DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition or DTC's listed above are present or can be duplicated, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-032-05 > Aug > 05 > Engine Controls - MIL ON/Misfire DTC's Set > Page 3230 REPAIR PROCEDURE NOTE: When first operating a brand new SRT, error messages will occur before PCM/TCM software is loaded into memory ("Download Error Reconnect/Retry" - will be displayed on the screen). Software must be downloaded from TechTOOLS before the SRT will be functional. This error will no longer display after the first download of vehicle software. TechTOOLS TO SRT SOFTWARE DOWNLOAD PROCEDURE 1. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 2. Perform a module scan of the vehicle you are working on to determine the current level Part Number of the PCM/TCM. This part number will be needed at a later point in this procedure to help identify the correct software to download from TechTOOLS. The SRT or DRBIII(R) w/CH8425 PCMCIA card can be used to ID the controller. 3. Log on to DealerCONNECT and navigate to TechTOOLS located within the Service tab. 4. Connect the SRT to a vehicle using the vehicle interface cable (CH8432-2). The SRT receives power from the vehicle through the 16-way data link connector. NOTE: As an alternate power source, the Diagnostic and Reprogramming Tool (DART) power supply cable p/n OT237497 can be optionally used to power the SRT with the DRBIII(R)/CoPilot power supply. This option is useful when downloading software and taking the SRT to a remote location for vehicle reprogramming. 5. Connect the SRT to the DealerCONNECT client using the serial interface cable (CH8432-1). The SRT receives vehicle reprogramming files from TechTOOLS through this cable. 6. Use the "Device Options" tab found in TechTOOLS and select Com Port to SRT. Follow any screen prompts to RELAUNCH TechTOOLS as necessary. 7. Identify the vehicle by using the YME (Year/Model/Engine) selection in TechTOOLS. NOTE: TechTOOLS cannot automatically read vehicle information (VIN) from these models. 8. Select the "Show Updates" button in TechTOOLS. 9. TechTOOLS will list the part numbers and descriptions of software available for download into the SRT based on the YME you selected. NOTE: Software availability will always be referenced by a Service Bulletin. 10. Select the appropriate software (based on Part Number recorded in step 2) for download into the SRT. 11. Select the "Download to SRT" button in the TechTOOLS screen. 12. Follow any prompts seen on TechTOOLS or the SRT screen. 13. When the software download process to the SRT is complete, disconnect the SRT from the DealerCONNECT client. NOTE: The process just completed only programs the SRT with vehicle software. SRT TO VEHICLE REPROGRAMMING PROCEDURES Once the SRT is loaded with vehicle software, it can be taken to the vehicle(s) that require update based on applicable Service Bulletins. NOTE: The software that is loaded into the SRT will stay in memory indefinitely. This provides a means for reprogramming multiple vehicles over a wide time expanse without having to reload vehicle software into the SRT 1. Connect the SRT to the vehicle with the vehicle interface cable (CH8432-2). Connect both (16-way and 12-way) data link connectors to the vehicle. The SRT is powered by the 16-way data link connector and vehicle communication (reprogramming) occurs through the 12-way data link connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-032-05 > Aug > 05 > Engine Controls - MIL ON/Misfire DTC's Set > Page 3231 CAUTION: Do not disconnect either data link connector until the reprogramming process is completed. 2. The SRT will boot up after connecting it to the vehicle data link connectors. 3. Follow all screen prompts until the reprogramming function is complete. 4. When the reprogramming function is complete, record the new part number for the Authorized Modification label. 5. After the new part number is recorded, turn off the ignition and remove the SRT from the vehicle. NOTE: The following step is required by law. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3237 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3238 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3239 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3240 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3241 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3242 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3243 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3244 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3245 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3246 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3247 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3248 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3249 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3250 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3251 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3252 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3253 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3254 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3255 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-05 > Aug > 05 > Engine Controls - MIL ON/Misfire DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/Misfire DTC's Set NUMBER: 18-032-05 GROUP: Vehicle Performance DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-028-02 DATED SEPTEMBER 16, 2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THIS SERVICE BULLETIN PROVIDES AN UPDATE TO CONFORM TO THE TechCONNECT FLASH PROCESS. SUBJECT: Flash: MIL Illumination - Misfire Diagnostic Trouble Codes (DTC's) P0300, P0301, P0302, P0303, P0304 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM). MODELS: 2002 - 2003 (ST) Sebring/Stratus Coupe NOTE: This information applies to vehicles equipped with a 2.4L engine (sales code EY7) and manual transaxle built prior to October 1, 2002 (MDH1001XX) or with an automatic transaxle built prior to September 1, 2002 (MDH0901XX). SYMPTOM/CONDITION: The Malfunction Indicator Lamp (MIL) may illuminate due to one or more of the DTC's shown. The DTC('s) may be intermittent and provide no symptoms other than MIL Illumination. DIAGNOSIS: Using the DRBIII(R) and CH8425 PCMCIA Diagnostic Card check for DTC's. If other DTC's are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the condition or DTC's listed above are present or can be duplicated, perform the Repair Procedure. PARTS REQUIRED SPECIAL TOOLS/EQUIPMENT REQUIRED Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-05 > Aug > 05 > Engine Controls - MIL ON/Misfire DTC's Set > Page 3260 REPAIR PROCEDURE NOTE: When first operating a brand new SRT, error messages will occur before PCM/TCM software is loaded into memory ("Download Error Reconnect/Retry" - will be displayed on the screen). Software must be downloaded from TechTOOLS before the SRT will be functional. This error will no longer display after the first download of vehicle software. TechTOOLS TO SRT SOFTWARE DOWNLOAD PROCEDURE 1. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 2. Perform a module scan of the vehicle you are working on to determine the current level Part Number of the PCM/TCM. This part number will be needed at a later point in this procedure to help identify the correct software to download from TechTOOLS. The SRT or DRBIII(R) w/CH8425 PCMCIA card can be used to ID the controller. 3. Log on to DealerCONNECT and navigate to TechTOOLS located within the Service tab. 4. Connect the SRT to a vehicle using the vehicle interface cable (CH8432-2). The SRT receives power from the vehicle through the 16-way data link connector. NOTE: As an alternate power source, the Diagnostic and Reprogramming Tool (DART) power supply cable p/n OT237497 can be optionally used to power the SRT with the DRBIII(R)/CoPilot power supply. This option is useful when downloading software and taking the SRT to a remote location for vehicle reprogramming. 5. Connect the SRT to the DealerCONNECT client using the serial interface cable (CH8432-1). The SRT receives vehicle reprogramming files from TechTOOLS through this cable. 6. Use the "Device Options" tab found in TechTOOLS and select Com Port to SRT. Follow any screen prompts to RELAUNCH TechTOOLS as necessary. 7. Identify the vehicle by using the YME (Year/Model/Engine) selection in TechTOOLS. NOTE: TechTOOLS cannot automatically read vehicle information (VIN) from these models. 8. Select the "Show Updates" button in TechTOOLS. 9. TechTOOLS will list the part numbers and descriptions of software available for download into the SRT based on the YME you selected. NOTE: Software availability will always be referenced by a Service Bulletin. 10. Select the appropriate software (based on Part Number recorded in step 2) for download into the SRT. 11. Select the "Download to SRT" button in the TechTOOLS screen. 12. Follow any prompts seen on TechTOOLS or the SRT screen. 13. When the software download process to the SRT is complete, disconnect the SRT from the DealerCONNECT client. NOTE: The process just completed only programs the SRT with vehicle software. SRT TO VEHICLE REPROGRAMMING PROCEDURES Once the SRT is loaded with vehicle software, it can be taken to the vehicle(s) that require update based on applicable Service Bulletins. NOTE: The software that is loaded into the SRT will stay in memory indefinitely. This provides a means for reprogramming multiple vehicles over a wide time expanse without having to reload vehicle software into the SRT 1. Connect the SRT to the vehicle with the vehicle interface cable (CH8432-2). Connect both (16-way and 12-way) data link connectors to the vehicle. The SRT is powered by the 16-way data link connector and vehicle communication (reprogramming) occurs through the 12-way data link connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-032-05 > Aug > 05 > Engine Controls - MIL ON/Misfire DTC's Set > Page 3261 CAUTION: Do not disconnect either data link connector until the reprogramming process is completed. 2. The SRT will boot up after connecting it to the vehicle data link connectors. 3. Follow all screen prompts until the reprogramming function is complete. 4. When the reprogramming function is complete, record the new part number for the Authorized Modification label. 5. After the new part number is recorded, turn off the ignition and remove the SRT from the vehicle. NOTE: The following step is required by law. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3267 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3268 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3269 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3270 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3271 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3272 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3273 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3274 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3275 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3276 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3277 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3278 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3279 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3280 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3281 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3282 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3283 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3284 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3285 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage NUMBER: 21-021-05 GROUP: Transmission DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-003-02, DATED JULY 29, 2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS, REVISED DISCUSSION AND REVISED PARTS REQUIRED SECTION. SUBJECT: ATF+4 Usage OVERVIEW: This bulletin provides information about ATF+4 usage in ST22 models. MODELS: 2001 - **2005** (ST) Sebring/Stratus Coupe DISCUSSION: ATF+4 (type 9602) is approved for use in Sebring/Stratus Coupe power steering and automatic transaxles. The fluid is fully compatible in power steering systems and no additional maintenance information is required. When using ATF+4 in automatic transaxles, the following information is required for proper service and maintenance. SCHEDULED MAINTENANCE When using ATF+4 as a complete fill in Sebring/Stratus Coupe models, the maintenance for schedule A is changed to a 60,000 mile fluid replacement interval. Schedule B remains the same as listed in the owners manual. The owner should be notified about this schedule change when ATF+4 is used as a complete fill. NOTE: Using ATF+4 for top off will not change the original characteristics of the factory fill or original maintenance schedule. GENERAL SERVICE FILL ATF+4 is fully compatible for top off or for any transaxle service procedures that would require fluid fill or fluid replacement. Special considerations are required if a new torque converter is installed. TORQUE CONVERTER REPLACEMENT If a new torque converter is installed, ATF+4 can be used however, green torque converter shudder MAY be experienced. If green torque converter shudder is experienced, it will be eliminated over time as the torque converter clutches wear or burnish in. If shudder occurs, the vehicle can be driven (in torque converter partial lockup) until the condition is eliminated. **The table below lists the speeds to drive the vehicle to achieve torque converter partial lock up. If customer concerns arise due to green torque converter shudder and will not accept the normal burnishing procedure, use the following procedure.** NOTE: **To eliminate any concerns of green torque converter shudder, the transaxle can be filled with Diamond SPIII fluid during the initial fill**. 1. Drain and refill the transaxle with a minimum of 80% Diamond SPIII Transmission Fluid. NOTE: **Diamond SPIll fluid is available from Mitsubishi dealers.** 2. Warm the transaxle (by driving) to a minimum of 40° C (104° F). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 3301 3. Drive the vehicle for 50 kilometers (30 miles) in a speed range to keep the transaxle torque converter in partial lock up. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 3302 Fluid - A/T: Technical Service Bulletins A/T - ATF Fluid Coloration/Filling Precautions NUMBER: 21-003-03 GROUP: Transmission DATE: Mar. 28, 2003 SUBJECT: Automatic Transmission Fluid (ATF) Color MODELS: 2003 (ST) Sebring Coupe/Stratus Coupe NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION (SALES CODES DGI, DGB, OR DHD) BUILT ON AND INCLUDING FEBRUARY 7, 2003 THROUGH AND INCLUDING MARCH 3, 2003. DISCUSSION: Automatic Transmission Fluid (ATF) delivery to the assembly plant did not have the appropriate red dye added during the refining process. The ATF color for the models listed above appears clear to slightly yellow/orange instead of the typical red color. Laboratory testing has confirmed the ATF meets all specifications and does not create any performance issues. It is not necessary to change the transmission fluid due to the lack of red dye. Since the fluid is nearly clear, it is difficult to see on the dipstick. When checking fluid level on one of these models, carefully check the dip stick level to avoid overfilling the transmission. POLICY: Information Only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 3303 Fluid - A/T: Technical Service Bulletins A/T, Power Steering - ATF+4 Fluid Usage NUMBER: 21-003-02 GROUP: Transmission DATE: Jul. 29, 2002 SUBJECT: ATF+4 Usage OVERVIEW: This bulletin provides information about ATF+4 usage in ST22 models. MODELS: 2001 - 2003 (ST) Sebring/Stratus Coupe DISCUSSION: ATF+4 (type 9602) is approved for use in Sebring/Stratus Coupe power steering and automatic transaxles. The fluid is fully compatible in power steering systems and no additional maintenance information is required. When using ATF+4 in automatic transaxles, the following information is required for proper service and maintenance. SCHEDULED MAINTENANCE When using ATF+4 as a complete fill in Sebring/Stratus Coupe models, the maintenance for schedule A is changed to a 60,000 mile fluid replacement interval. Schedule B remains the same as listed in the owners manual. The owner should be notified about this schedule change when ATF+4 is used as a complete fill. NOTE: USING ATF+4 FOR TOP OFF WILL NOT CHANGE THE ORIGINAL CHARACTERISTICS OF THE FACTORY FILL OR ORIGINAL MAINTENANCE SCHEDULE. GENERAL SERVICE FILL ATF+4 is fully compatible for top off or for any transaxle service procedures that would require fluid fill or fluid replacement. Special considerations are required if a new torque converter is installed. TORQUE CONVERTER REPLACEMENT If a new torque converter is installed, ATF+4 can be used however, green torque converter shudder MAY be experienced. If green torque converter shudder is experienced, it will be eliminated over time as the torque converter clutches wear or burnish in. If shudder occurs, the vehicle can be driven (in torque converter partial lockup) until the condition is eliminated. If customer concerns arise due to green torque converter shudder use the following procedure. NOTE: TO ELIMINATE ANY CONCERNS OF GREEN TORQUE CONVERTER SHUDDER, THE TRANSAXLE CAN BE FILLED WITH DIAMOND SPIII FLUID PN 05073942AA DURING THE INITIAL FILL. 1. Drain and refill the transaxle with a minimum of 80% Diamond SPIII Transmission Fluid pn 05073942AA. 2. Warm the transaxle (by driving) to a minimum of 40 degrees C (104 degrees F). 3. Drive the vehicle for 50 kilometers (30 miles) in a speed range as shown to keep the transaxle torque converter in partial lock up. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage > Page 3304 PARTS REQUIRED POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications Fluid - A/T: Pressure, Vacuum and Temperature Specifications Line pressure ....................................................................................................................................... .............................. 1,010 - 1,050 kPa (147 - 152 psi) A/T fluid temperature sensor @ 0 °C (32 °F) ..................................................................................................................................... ................................................... 16.7 - 20.5 ohms @ 20 °C (68 °F) ................................................... ....................................................................................................................................... 7.3 - 8.9 ohms @ 40 °C (104 °F) ....................................................................................................................... ................................................................. 3.4 - 4.2 ohms @ 60 °C (140 °F) ....................................... ................................................................................................................................................. 1.9 2.2 ohms @ 80 °C (176 °F) ................................................................................................................. ....................................................................... 1.0 - 1.2 ohms @ 100 °C (212 °F) ............................... ................................................................................................................................................... 0.57 0.69 ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3307 Fluid - A/T: Capacity Specifications Fluid Capacity ...................................................................................................................................... ...................................................... 7.7Liters (8.1 Qt) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3308 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................... ............................... Mitsubishi Genuine ATF SP III Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement Fluid - A/T: Service and Repair A/T Fluid Replacement Automatic Transmission Fluid Replacement Procedure If you have an transmission fluid changer, use this chapter to replace the transmission fluid. If you do not have an transmission fluid changer, replace the transmission fluid by the following procedure. 1. Disconnect the hose show in the illustration which connects the transaxle and the oil cooler (inside the radiator). Place a container under the hose to collect the discharge. Caution: The engine should be stopped within one minute after it is started. If all the transmission fluid has drained out before then, the engine should be stopped at that point. 2. Start the engine and let the transmission fluid drain out. - Running Conditions: "N" range with engine idling Note: Approximately 3.5 dm ( 3.7 quarts ) of transmission fluid should be removed. 3. Remove the drain plug from the bottom of the transaxle case to drain the transmission fluid. - Approximately 2.0 dm ( 2.1 quarts ) of transmission fluid should be removed. 4. Install the drain plug with a new gasket, and tighten it to the specified torque. - Tighten torque 32 ± 2 Nm ( 24 ft lbs ). Caution: Stop pouring if the full volume of transmission fluid cannot be added. 5. Add new transmission fluid ( DIAMOND ATF SP III or equivalent ) through the oil filler tube. - Approximately 5.5 dm ( 5.8 quarts ) transmission fluid should be added. 6. Repeat the procedure in step 2, ( to pump out the rest of the contaminated transmission fluid ). 7. Add new transmission fluid ( DIAMOND ATF SP III or equivalent ) through the oil filler tube. - Approximately 3.5 dm ( 3.7 quarts ) transmission fluid should be added. Note: Check for contamination or a burnt odor. If the transmission fluid is contaminated or burnt, repeat steps 6 and 7 before proceeding to step 8. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement > Page 3311 8. Reconnect the hose which was disconnect in step 1 above, and firmly replace the dipstick. 9. Start engine and run it at idle for one to two minutes. 10. Move the selector lever through all positions, and then move it to the "N" position. 11. Check that the transmission fluid level is at the "COLD" mark on the dipstick. If the level is less than this, add transmission fluid. 12. Drive the vehicle until the transmission fluid temperature ruses to the normal operating temperature ( 70 - 80 ° C ( 158 - 176 ° F )) and then check the transmission fluid level again. The transmission fluid level must be at the "HOT" mark. Note: The A/T fluid temperature is measured with scan tool MB991502 ( MUT II ). Note: The "COLD" level is for reference only, the "HOT" level should be regarded as the standard level. Note: If it takes some amount of time until the A/T fluid reaches its normal operating temperature ( 70 - 80 ° C ( 158 - 176 ° F )), check the A/T fluid level by refering to the diagram. 13. When the transmission fluid is less than the specified level, add transmission fluid. When the transmission fluid is greater than the specified level, drain the excess fluid through the drain plug to adjust the transmission fluid to the specified level. 14. Firmly insert the dipstick into the oil filler tube. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement > Page 3312 Fluid - A/T: Service and Repair A/T Fluid Check A/T FLUID CHECK 1. Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 - 80 °C (158 - 176 °F)]. NOTE: The A/T fluid temperature is measured with scan tool MB991502 (MUT-II). NOTE. If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 - 80'C (158 176 OF)], check the A/T fluid level by referring to the left diagram. 2. Park the vehicle on a level surface. 3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then move the selector lever to the "N" position. 4. After wiping off any dirt around the dipstick, remove the dipstick and check the condition of the A/T fluid. NOTE: If the A/T fluid smells as if it is burnt, it means that the A/T fluid has been contaminated by fine particles from the bushings and friction materials, A transaxle overhaul and cooler line flushing may be necessary. 5. Check that the A/T fluid level is at the "HOT" mark on the dipstick. If the A/T fluid level is less than this, add DIAMOND ATF SIP III or equivalent A/T fluid until the level reaches the "HOT" mark. NOTE: If the A/T fluid level is too low, the oil pump will draw in air along with the A/T fluid, which will cause bubbles to form. If the A/T fluid level is too high, rotating components inside the transaxle will chum the fluid and air into a foamy liquid. Both conditions (level too low or too high) will cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. NOTE: In either case, air bubbles can interfere with normal valve, clutch, and brake operation. Also, foaming can cause A/T fluid to escape from the transaxle vent where it may be mistaken for a leak. 6. Securely insert the dipstick. NOTE: The A/T fluid should always be replaced under the following conditions: When troubleshooting the transaxle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Replacement > Page 3313 - When overhauling the transaxle. - When the A/T fluid is noticeably dirty or burnt (driving under severe conditions). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Valve Body Cover ................................................................................................................................ ................................. 11 + / - Nm ( 95 + / - 9 in lbs ) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Diagrams Fluid Pump: Diagrams OIL PUMP DISASSEMBLY AND ASSEMBLY Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams Output Shaft: Diagrams OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Diagrams > Page 3323 Output Shaft: Description and Operation The output shaft speed sensor cannot be checked as an individual part after the sensor has been removed. Using scan tool MB991 502, check whether diagnosis code 23 is set while the sensor is installed. If this code is set, refer to Combination meter diagnosis - Symptom Procedure 1. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams Planetary Gears: Diagrams PLANETARY GEAR DISASSEMBLY AND ASSEMBLY Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection F4A42 - Automatic Transmission INSPECTION SHIFT SWITCH ASSEMBLY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Testing and Inspection Transmission Temperature Sensor/Switch: Testing and Inspection A/T FLUID TEMPERATURE SENSOR CONTINUITY CHECK 1. Remove the A/T fluid temperature sensor. 2. Measure the resistance between terminals No. 1 and No.2 of the A/T control solenoid valve assembly connector. Standard value: 3. If the A/T fluid temperature sensor resistance is not consistent with the fluid temperature, replace A/T fluid temperature sensor. NOTE: The N range indicator light on the combination meter flashes when the temperature reaches approximately 125°C (257°F) or higher, and then Stops flashing when the temperature drops below approximately 115°C (23-wF). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Specifications Shift Interlock: Specifications Key interlock and shift lock mechanisms Key interlock cable .............................................................. .................................................................................................... 12 ± 2 Nm (102 ± 22 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Specifications > Page 3344 Shift Interlock: Service and Repair A/T KEY INTERLOCK AND SHIFT LOCK MECHANISMS REMOVAL AND INSTALLATION CAUTION: When removing and installing the transmission control cable and shift lock cable unit, be careful not to impact the SRS-ECU. INSTALLATION SERVICE POINTS >>A<< SHIFT LOCK CABLE (SELECTOR LEVER SIDE) INSTALLATION 1. Shift the selector lever in the "P" position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Specifications > Page 3345 2. Fasten the shift lock cable at the position where the end of the shift lock cable is positioned above the red marking on the lock cam. >>B<< KEY INTERLOCK CABLE (STEERING LOCK CYLINDER SIDE) INSTALLATION Turn the ignition key to the "LOCK" (OFF) position and install the key interlock cable. >>C<< KEY INTERLOCK CABLE (SELECTOR LEVER SIDE) INSTALLATION 1. Shift the selector lever to the "P" position. 2. Turn the ignition key to the "LOCK" (OFF) position. 3. Slide the washer and spring toward the lock cam, insert the cable into the stand off bracket and release the spring. 4. Lightly push the key interlock cable into the key interlock cable housing toward the arrow (A) direction until the cable movement stops and the cable end eye is aligned with the shaft on the lock cam. Tighten the lock nut. Snap the cable end eye onto the shaft of the locking cam. Tightening torque: 12 ± 2 Nm (107 ± 17 in. lbs.) INSPECTION Check the cable assembly for function and for damage. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Testing and Inspection Shifter A/T: Testing and Inspection F4A42 - Automatic Transmission SELECTOR LEVER OPERATION CHECK 1. Apply the parking brake, and check that the selector lever moves smoothly and accurately to each position. 2. Check that the engine starts when the selector lever is at the "N" or "P" position, and that it does not start when -the selector lever is in any other position. 3. Start the engine, release the parking brake, and check that the vehicle moves forward when the selector lever is moved from "N" position to "D," "3,"Y" or "U position or to 1st or 2nd gear in Sports mode, and that the vehicle reverses when the selector lever is moved to "13" position. 4. Stop the engine. 5. Turn the ignition switch to the "ON" position, and check that the backup lamp illuminates when the selector lever is shifted from "P" to "R" position. NOTE: The A/T mis-operation prevention mechanism is provided so that the selector lever cannot be moved from the 7" position if the ignition switch is at a position other than the "LOCK" (OFF) position and the brake pedal is not depressed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Testing and Inspection > Page 3352 Shifter A/T: Service and Repair F4A42 - Automatic Transmission Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Testing and Inspection > Page 3353 DISASSEMBLY AND ASSEMBLY Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Shift lock cable .................................................................................................................................... .................................... 12 ± 2 Nm (102 ± 22 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Drive Plate Bolts .................................................................................................................................. ....................................... 49 ± 5 Nm ( 37 ± 2 ft lbs ) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection F4A42 - Automatic Transmission INSPECTION SHIFT SWITCH ASSEMBLY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Fastener Tightening Specification Transmission Mount: Specifications Fastener Tightening Specification FASTENER TIGHTENING SPECIFICATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Fastener Tightening Specification > Page 3371 Transmission Mount: Specifications Service Specification SERVICE SPECIFICATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 3372 Transmission Mount: Diagrams TRANSAXLE MOUNTING CAUTION: Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 3373 Transmission Mount: Service and Repair TRANSAXLE MOUNTING REMOVAL AND INSTALLATION CAUTION: Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body. INSTALLATION SERVICE POINT >>A<< TRANSAXLE MOUNT STOPPER INSTALLATION Clamp the transaxle mount stopper so that the arrow points in the direction as shown in the diagram. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Testing and Inspection Transmission Temperature Sensor/Switch: Testing and Inspection A/T FLUID TEMPERATURE SENSOR CONTINUITY CHECK 1. Remove the A/T fluid temperature sensor. 2. Measure the resistance between terminals No. 1 and No.2 of the A/T control solenoid valve assembly connector. Standard value: 3. If the A/T fluid temperature sensor resistance is not consistent with the fluid temperature, replace A/T fluid temperature sensor. NOTE: The N range indicator light on the combination meter flashes when the temperature reaches approximately 125°C (257°F) or higher, and then Stops flashing when the temperature drops below approximately 115°C (23-wF). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams Valve Body: Diagrams VALVE BODY Part 1 Of 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3383 Part 2 Of 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3384 Part 3 Of 3 DISASSEMBLY AND ASSEMBLY Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3385 Valve Body: Testing and Inspection F4A42 - Automatic Transmission SOLENOID VALVE CHECK 1. Use the scan tool to measure the ATF temperature and set the ATF temperature to 20°C (68°F). 2. Remove the A/T control solenoid valve assembly connector. 3. Measure the resistance between the solenoid valve terminals. Standard Values 4. Check that the measured values are within the standard values at Steps 1 and 2. 5. If within the standard value, check the power supply and the ground circuits. 6. If not within the standard value, drain the ATF and remove the valve body cover. 7. Disconnect the connectors of each solenoid valve. 8. Measure the resistance between terminals 1 and 2 of each solenoid valve. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3386 Standard value:..............2.7 - 3.4 Ohms [at 20°C (68°F)] 9. If the resistance is not within the standard value, replace the solenoid valve. 10. If within the standard value, check each wiring harness between A/T control solenoid valve assembly and each solenoid valve. If a problem is not found at the steps above, check the solenoid valve O-rings and replace if necessary. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3387 Valve Body: Service and Repair F4A42 - Automatic Transmission VALVE BODY (1 0f 3) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3388 VALVE BODY (2 0f 3) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3389 VALVE BODY (3 0f 3) VALVE BODY DISASSEMBLY AND ASSEMBLY SERVICE POINTS << A >> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 3390 SOLENOID VALVES REMOVAL Mark the solenoid valves with white paint to make assembly easier. >> A << SPRING STEEL BALL, DAMPING VALVE AND DAMPING VALVE SPRING INSTALLATION 1. Install the two steel balls and two springs to the inside valve body as shown. 2. Install the damping valve and spring to the inside valve body as shown. >> B << SPRING AND STEEL BALL INSTALLATION Install the three steel balls and two springs to the inside valve body as shown. >>C<< SOLENOID VALVES INSTALLATION 1. Apply ATF or petroleum jelly (Vaseline) to the O-ring and install carefully. 2. Install the solenoid valves by referring to the marks applied during disassembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Specifications > Fastener Tightening Specification Differential Assembly: Specifications Fastener Tightening Specification FASTENER TIGHTENING SPECIFICATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Specifications > Fastener Tightening Specification > Page 3395 Differential Assembly: Specifications Service Specification SERVICE SPECIFICATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation Axle Shaft: Service and Repair Removal and Installation Drive Shaft Assembly REMOVAL AND INSTALLATION / DRIVE SHAFT ASSEMBLY SERVICE POINTS << A >> DRIVESHAFT NUT REMOVAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3402 CAUTION: Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the driveshaft nut is loosened. << B >> LOWER ARM BALL JOINT/TIE ROD END DISCONNECTION CAUTION: Do not remove the nut from the ball joint. Loosen it and use special tool MB99111. or MB990635 to avoid possible damage to the ball joint threads. Hang special tools with rope or wire to prevent them from falling. << C >> DRIVESHAFT/DRIVESHAFT AND INNER SHAFT REMOVAL CAUTION: Do not damage the ABS rotor attached to the BJ outer race. 1. Use special tools M13991354, MB990242 and MB990767 to push the driveshaft out from the hub. CAUTION: Do not pull on the driveshaft; doing so will damage the TJ; be sure to use the pry bar. Do not insert the pry bar so deep as to damage the oil seal. Do not damage the transaxle oil seal with the spline of the driveshaft. 2. Insert a pry bar between the transaxle case and the driveshaft as shown to remove the driveshaft. <2.4L ENGINE, 3.01. ENGINE-LH> CAUTION: Do not damage the transaxle oil seal with the spline of the inner shaft. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3403 3. If the inner shaft and transaxle are tightly joined, tap the center bearing bracket lightly with a plastic hammer, etc. to remove the drive shaft and inner shaft from the transaxle. <3.0L ENGINE-RH> 4. Cover the transaxle case with a shop towel to prevent foreign material from entering it. CAUTION: Do not apply the vehicle weight to the wheel bearing while loosening the driveshaft nut. If, however, the vehicle weight must be applied to the bearing (in order to move the vehicle), temporarily secure the wheel bearing by using special tool MB990998. >> A << DRIVE SHAFT AND INNER SHAFT/DRIVE SHAFT INSTALLATION CAUTION: Do not damage the transaxle oil seal with the spline of the shaft. Do not damage the ABS rotor attached to the BJ outer race. >> B << DRIVE SHAFT NUT INSTALLATION 1. Face the flat side of a washer to a drive shaft nut to install CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when castle nut is loosened. 2. Tighten driveshaft nut fully, using the special tool M13990767. 3. If the position of the cotter pin holes does not match, tighten the nut up to 226 ± 29 Nm (167 ± 21 ft. lbs.) maximum. 4. Install the cotter pin in the first matching holes and bend it securely. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3404 Axle Shaft: Service and Repair Disassembly and Assembly Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3405 Drive Shaft Assembly Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3406 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3407 LUBRICATION POINTS DISASSEMBLY AND ASSEMBLY / DRIVE SHAFT ASSEMBLY SERVICE POINTS CAUTION: Never disassemble the BJ assembly when replacing the BJ boot. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3408 << A >> INNER SHAFT REMOVAL 1. Use special tool MB991248 or MD998801 to remove the inner shaft assembly and the seal plate from the TJ case. NOTE: Press the seal plate to deform it, and then press out the inner shaft. 2. Use special tool MB991248 or MD998801 to remove the inner shaft from the center bearing bracket. << B >> CENTER BEARING REMOVAL Use special tools MB990930 and MB990938 to press the center bearing out from the center bearing bracket. << C >> TJ BOOT REMOVAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3409 Wrap plastic tape around the spline part on the BJ assembly so that the TJ boot is not damaged when they are removed. >> A << DYNAMIC DAMPER/DAMPER BAND/TJ BOOT INSTALLATION 1. Install the dynamic damper in the position shown in the illustration. CAUTION: There should be no grease adhered to the rubber part of the dynamic damper. The damper band and the TJ boot band (small) are different in shape. Be careful not to assemble a wrong band by identifying a color of the band. 2. Secure the damper bands. 3. Wrap plastic tape around the shaft spline, and then install the TJ boot band (small) and TJ boot. >> B << SPIDER ASSEMBLY INSTALLATION CAUTION: The driveshaft joint uses special grease. Do not mix old and new or different types of grease. 1. Apply the repair kit grease to the spider axles and rollers of the spider assembly. 2. Face the chamfered portion of the spider assembly's spline toward the driveshaft, and then install the spider assembly to the driveshaft. >> C << CENTER BEARING INSTALLATION Use special tools MB990930 and MB990938 to press the center bearing into the center bearing bracket. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3410 >> D << DUST SEAL INNER/DUST SEAL OUTER INSTALLATION 1. Pack the specified grease in the places shown in the figure. Specified grease:................MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent Quantity:............14 - 20 grams (0.5 - 0.7 ounces) Quantity:............8 - 12 grams (0.3 - 0.4 ounces) CAUTION: Do not damage the rubber portion of the dust seal outer surface when packing the specified grease, otherwise grease will leak. 2. Use special tools MB990890 and MB990934 to press the oil seal into the center bearing bracket. 3. Apply the specified grease to the lip of the dust seal. NOTE: Do not apply the specified grease to the outside of the lip. Specified grease:................MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent >> E << INNER SHAFT INSTALLATION Use special tool MB991172 to hold the center bearing inner race, and then press-in the inner shaft. >> F << Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation > Page 3411 TJ CASE/INNER SHAFT ASSEMBLY INSTALLATION 1. Apply the specified grease to the inner shaft serration, and then press the inner shaft assembly into the TJ case. Specified grease:............MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent CAUTION: The driveshaft joint uses special grease. Do not mix old and new or different types of grease. 2. Fill the TJ case with repair kit grease and insert the driveshaft, and then refill the TJ case with repair kit grease. Quantity:............<2.4L ENGINE>100 ± 10 grams (3.5 ± 0.4 ounces) Quantity:............<3.0L ENGINE>105 ± 10 grams (3.7 ± 0.4 ounces) NOTE: The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. >> G << TJ BOOT BAND (SMALL)/TJ BOOT BAND (LARGE) INSTALLATION 1. Position the TJ outer race so that the distance between the boot bands is at the standard value. Standard value (A):...............85 ± 3 mm (3.3 ± 0.1. inch) 2. Remove part of the TJ outer race to release the air pressure inside the boot. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair Constant Velocity Joint Boot: Service and Repair BJ BOOT REPLACEMENT 1. Remove the boot bands (large and small). NOTE: The BJ boot bands cannot be re-used. 2. Remove the BJ boot. 3. Turn the adjusting bolt on the special tool so that the size of the opening (W) is at the standard value. Standard value (W):...........2.9 mm (0.1. inch) Tighten the adjusting bolt. Loosen the adjusting bolt. NOTE: The value of W will change by approximately 0.7 mm (0.03 inch) for each turn of the adjusting bolt. NOTE: The adjusting bolt should not be turned more than once. 4. Place the BJ boot band (small) against the projection at the edge. of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration. CAUTI0N: Secure the drive shaft in an upright position and clamp the part of the BJ boot band to be crimped securely in the jaws of the special tool MB991561. Crimp the BJ boot band until the special tool touches the stopper. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Page 3415 5. Use the special tool to crimp the BJ boot band (small). 6. Check that crimping amount (B) of the BJ boot band is at the standard value. Standard value (B):.........2.4 - 2.8 mm (0.1. - 0.1. inch) Readjust the value of (W) in step 4 according to the following formula, and then repeat the operation in step 6. W = 5.5 mm (0.22 inch) - B Example: If B = 2.9 mm (0.1. inch), then W = 2.6 mm (0.1. inch). Remove the BJ boot band, readjust the value of (W) in step 4 according to the following formula, and then repeat the operations in steps 5 and 6 using a new BJ boot band. W = 5.5 mm (0.22 inch) - B Example: If B = 2.3 mm (0.1. inch) then W = 3.2 mm (0.1. inch). 7. Check that the BJ boot band is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, remove it and then repeat the operations in steps 4 to 6 using a new BJ boot band. CAUTION: The drive shaft joint uses special grease. Do not mix old and new grease or different types of grease. 8. Fill the inside of the BJ boot with the specified amount of the repair kit grease. Grease quantity...........<2AL ENGINE>110 ± 10 grams (3.9 ± 0.4 ounces) Grease quantity...........<3.0L ENGINE> 120 ± 10 grams (4.2 ± 0.4 ounces) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Page 3416 9. Install the BJ boot band (large) so that clearance (C) between it and the BJ housing is at the standard value. Standard value (C):...........0.1. - 1.55 mm (0.004 - 0.061 inch) 10. Follow the same procedure as in step 3 to adjust the size of the opening (W) on the special tool MB991561 so that it is at the standard value. Standard value (W):...........3.2 mm (0.1. inch) 11. Place the BJ boot band (large) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (D) in the illustration. 12. Use the special tool MB991561 to crimp the BJ boot band (large) in the same way as in step 5. 13. Check that the crimping amount (E) of the BJ boot band is at the standard value and that the crimping amount (F) of the BJ boot band is at the limited value. Standard value (E):.............2.4 - 2.8 mm (0.1. - 0.1. inch) Limited value(F):....................9.5 mm (0.40 inch) Readjust the value of (W) in step 1. according to the following formula, and then repeat the operation in step 12. W = 5.8 mm (0.23 inch) - E Example: If E = 2.9 mm (0.1. inch), then W = 2.9 mm (0.1. inch). Remove the BJ boot band, readjust the value of (W) in step 10 according to the following formula, and then repeat the operations in steps 10 and 10 using a new BJ boot band. W = 5.8 mm (0.23 inch) - E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Page 3417 Example: If E = 2.3 mm (0.1. inch) then W = 3.5 mm (0.15 inch). 14. Check that the BJ boot band is not sticking out past the place where it has been installed. If the BJ boot band is sticking out, remove it and then repeat the operations in steps 11 to 13 using a new BJ boot band. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Nut ............................................................................................................................................... .............................. 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 3422 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front Wheel Bearing Breakaway Torque Check INSPECTION WHEEL BEARING BREAKAWAY TORQUE CHECK 1. Install the special tools MB990998 and MB990326 to the front hub assembly and tighten the nut to the specified torque. Tightening torque: 226 ± 29 Nm (167 ± 21 ft. lbs.) 2. Measure the wheel bearing breakaway torque with special tools. Limit: 1.0 Nm (9 inch lbs.) or less 3. Wheel bearing breakaway torque must be under the limit value and there should be no roughness when rotating the hub. Wheel Bearing End Play Check WHEEL BEARING END PLAY CHECK 1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the end play while moving the hub in the axial direction. Limit: 0.05 mm (0.002 inch) 4. If end play exceeds the limit, replace the front hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 3425 Wheel Bearing: Testing and Inspection Rear Rear Hub Rotary-Sliding Resistance Check REAR HUB ROTARY-SLIDING RESISTANCE CHECK 1. For vehicles with rear disc brakes, remove the Caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. After turning the hub a few times to seat the bearing, wind a rope around the hub bolt and turn the hub by pulling at a 90 degree angle with a spring balance. Measure to determine whether or not the rotary-sliding resistance of the rear hub is at the limit value. Limit:...............18 Nm (13 ft. lbs.) 4. If the rotary-sliding resistance exceeds the limit value, replace the rear hub assembly. Wheel Bearing End Play Check 1. For vehicles with rear disc brakes, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. Check the bearing's end play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is end play. Limit:................0.05 mm (0.002 inch) 4. If the play exceeds the limit value, replace the rear hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Ball Joint Pinch Bolt ............................................................................................................................. .................................. 108 ± 10 Nm (80 ± 7 ft. lbs.) Wheel Hub Mounting Bolts ........................................................................................................................................................... 88 ± Nm (65 ± 7 ft. lbs.) Axle Nut ........................................................................................................ ..................................................................... 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Axle Hub Assembly - Front / REMOVAL AND INSTALLATION CAUTION: For vehicles with ABS, be careful when handling the projection at the tip of the speed sensor so as not to damage it by striking against other parts. The front hub assembly should not be dissembled. When removing the front hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the front hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play. REMOVAL SERVICE POINTS << A >> DRIVE SHAFT NUT REMOVAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 3431 CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when drive shaft nut is loosened. << B >> TIE ROD END DISCONNECTION CAUTION Do not remove nut from ball joint but loosen it and use special tools instead to avoid possible damage to ball joint threads. Hang special tools with ropes to prevent them from failing. INSTALLATION SERVICE POINT >> A << DRIVE SHAFT NUT INSTALLATION CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when castle nut is loosened. 1. Direct the flat side of a washer to a drive shaft nut to install. 2. Tighten driveshaft nut fully with special tools. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 3432 Wheel Hub: Service and Repair Rear Axle Hub Assembly - Rear / REMOVAL AND INSTALLATION REMOVAL SERVICE POINTS << A >> CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 3433 << B > ABS ROTOR REMOVAL << C >> BACKING PLATE REMOVAL Remove the backing plate and suspend it. INSTALLATION SERVICE POINT >> A << ABS ROTOR INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel/Drive Plate Bolts ........................................................................................................................................................ 132 ± 5 Nm ( 98 ± 4 ft lbs ) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications Manual Transmission .......................................................................................................................... SAE 75W-90 or 75W/85W API Classification GL-4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Transaxle Oil Level Check Fluid - M/T: Service and Repair Transaxle Oil Level Check TRANSAXLE OIL LEVEL CHECK 1. Remove the filler plug. 2. Check that the oil level is up to the lower edge of the filler plug hole. 3. Check that the oil is not noticeably dirty. 4. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Transaxle Oil Level Check > Page 3443 Fluid - M/T: Service and Repair Transaxle Oil Replacement TRANSAXLE OIL REPLACEMENT 1. Remove the filler plug. 2. Remove the drain plug and drain the oil. 3. Tighten the drain plug to the specified torque. Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.) 4. Fill with gear oil SAE 75W - 90W or 75W - 85W conforming to API classification until the level comes to the lower portion of filler plug hole. Quantity: 2.2 dm3 (2.3 quarts) 2.8 dm3 (3.0 quarts) 5. Tighten the filler plug to the specified torque. Tightening torque: 32 ± 2 Nm (24 ± 1 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Specifications Input Shaft: Specifications Input shaft end play .................................................................................................................................... 0.05 - 0.17 mm (0.020 - 0.0067 inch) Input shaft front bearing end play ........................................................................................................................................... 0 - 0.12 mm (0 - 0.0047 inch) Input shaft rear bearing end play ............................................................................................................................................. 0 - 0.12 mm (0 - 0.0047 inch) Input shaft 5th speed gear end play ......................................................................................................................................... 0 - 0.09 mm (0 - 0.0055 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications Output Shaft: Specifications Output shaft roller bearing inner race end play ...................................................................................................... 0 - 0.12 mm (0 - 0.0047 inch) Output shaft ball bearing end play ......................................................................................................................... 0 - 0.09 mm (0 0.0035 inch) Output shaft preload ................................................................................................................................. 0.13 - 0.18 mm (0.0051 - 0.0071 inch) Output shaft taper roller bearing end play .............................................................................................................. 0 - 0.09 mm (0 - 0.0035 inch) Output shaft 3rd speed gear end play ...................................................................................................................................... 0 - 0.09 mm (0 - 0.0035 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Select lever attaching bolt ...................................................................................................................................................... 6.0 ± 2.0 Nm (53 ± 18 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Specifications Shift Cable: Specifications M/T cable attaching bolt .......................................................................................................................................................... 12 ± 2 Nm (102 ± 22 in. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection F4A42 - Automatic Transmission INSPECTION SHIFT SWITCH ASSEMBLY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Testing and Inspection Transmission Temperature Sensor/Switch: Testing and Inspection A/T FLUID TEMPERATURE SENSOR CONTINUITY CHECK 1. Remove the A/T fluid temperature sensor. 2. Measure the resistance between terminals No. 1 and No.2 of the A/T control solenoid valve assembly connector. Standard value: 3. If the A/T fluid temperature sensor resistance is not consistent with the fluid temperature, replace A/T fluid temperature sensor. NOTE: The N range indicator light on the combination meter flashes when the temperature reaches approximately 125°C (257°F) or higher, and then Stops flashing when the temperature drops below approximately 115°C (23-wF). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Testing and Inspection Transmission Mode Switch: Testing and Inspection F4A42 - Automatic Transmission INSPECTION SHIFT SWITCH ASSEMBLY CONTINUITY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Transmission Speed Sensor: Locations View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Testing and Inspection Transmission Temperature Sensor/Switch: Testing and Inspection A/T FLUID TEMPERATURE SENSOR CONTINUITY CHECK 1. Remove the A/T fluid temperature sensor. 2. Measure the resistance between terminals No. 1 and No.2 of the A/T control solenoid valve assembly connector. Standard value: 3. If the A/T fluid temperature sensor resistance is not consistent with the fluid temperature, replace A/T fluid temperature sensor. NOTE: The N range indicator light on the combination meter flashes when the temperature reaches approximately 125°C (257°F) or higher, and then Stops flashing when the temperature drops below approximately 115°C (23-wF). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Overall View View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake tube flare nut ............................................................................................................................. ......................................... 15 ± 2 Nm (11 ± 1 ft. lbs.) Hydraulic unit bracket bolt ........................................................................................................................................................... 30 ± 5 Nm (22 ± 4 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 3503 Hydraulic Control Assembly - Antilock Brakes: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Testing and Inspection > Anti-Lock Braking System (ABS) Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection Anti-Lock Braking System (ABS) HYDRAULIC UNIT CHECK Required Special Tool: ^ MB991502: Scan Tool (MUT-II) CAUTION: ^ The roller of the braking force tester and the tire should be dry during testing. ^ When testing the front brakes, apply the parking brake. When testing the rear brakes, stop the front wheels with chocks. 1. Jack up the vehicle. Then support the vehicle with rigid racks at the specified jack-up points or place the front or rear wheels on the rollers of the braking force tester. 2. Release the parking brake, and feel the drag force (drag torque) on each road wheel. When using the braking force tester, take a reading of the brake drag force. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Testing and Inspection > Anti-Lock Braking System (ABS) > Page 3506 8. After inspection, disconnect the scan tool immediately after turning the ignition switch to the "LOCK" (OFF) position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Testing and Inspection > Anti-Lock Braking System (ABS) > Page 3507 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection Traction Control System (TCL) HYDRAULIC UNIT CHECK Required Special Tool: ^ MB991502: Scan Tool CAUTION: ^ The roller of the braking force tester and the tire should be dry during testing. ^ When testing the front brakes, apply the parking brake. When testing the rear brakes, stop the front wheels with chocks. 1. Jack-up the vehicle. Then support the vehicle with rigid racks at the specified jack-up points or place the front or rear wheels on the rollers of the braking force tester. 2. Release the parking brake, and feel the drag force (drag torque) on each road wheel. When using the braking force tester, take a reading of the brake drag force. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 3. Turn the ignition switch to the "LOCK" (OFF) position and set scan tool MB991502 as shown in the illustration. 4. After checking that the shift lever/selector lever is in neutral, start the engine. 5 Use scan tool MB991502 to force-drive the actuator. NOTE: The TCL system will switch to the scan tool mode and the ABS warning light will illuminate. NOTE: When the TCL has been interrupted by the fail-safe function, scan too/ MB991502 actuator testing cannot be used. 6. Turn the wheel by hand and check the change in braking force; Use a braking force tester. The braking force reading value should change when the actuator test is carried out. The result should be as shown in the diagram above. 7. If the result of inspection is abnormal, replace the hydraulic unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Testing and Inspection > Page 3508 Hydraulic Control Assembly - Antilock Brakes: Service and Repair HYDRAULIC UNIT REMOVAL AND INSTALLATION NOTE: The ABS-ECU is integrated in the hydraulic unit. REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Testing and Inspection > Page 3509 INSTALLATION SERVICE POINT >>A<< BRAKE TUBE INSTALLATION Connect the tubes to the hydraulic unit as shown in the illustration. 1. To the proportioning valve (rear brake: LH) 2. To the proportioning valve (rear brake: RH) 3. From the master cylinder (primary) 4. From the master cylinder (secondary) 5. To the front brake (RH) 6. To the front brake (LH) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Wheel speed sensor internal resistance .................................................................................................................................................... 1.28 - 1.92 k Ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 3514 Wheel Speed Sensor: Mechanical Specifications Distance between wheel speed sensor installation surface and ABS rotor tooth top; 28.2 - 28.5 mm (1.11 - 1.12 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 3515 Wheel Speed Sensor: Locations View c Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 3516 View d Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 3517 Wheel Speed Sensor: Testing and Inspection WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT Required Special Tool ^ MB991219: Inspection Harness 1. Lift up the vehicle, and release the parking brake. 2. Disconnect the ABS DECO connector A-02, and then use special tool MB991219 to measure the output voltage at the harness side connector. 3. Manually turn the wheel to be measured 112 to 1 burnt second. Measure the output voltage with a voltmeter or oscilloscope. Output voltage: ^ Minimal voltmeter reading: 42 mV ^ Maximum voltmeter reading: 300 mV ^ Minimal oscilloscope reading: 120 mV ^ Maximum oscilloscope reading: 600 mV Probable causes of low output voltage ^ Wheel speed sensor pole piece-to-ABS rotor clearance too large ^ Faulty wheel speed sensor NOTE: Check the connection of the sensor harness and connector before using the oscilloscope. 4. To observe the waveform with an oscilloscope: ^ Front Wheels: Shift into low gear and drive the wheels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 3518 ^ Rear Wheels: Turn the wheels manually at a constant speed NOTE: The output waveform is low when the wheel speed is low. Similarly, it will be higher as the wheel speed increases. Waveform may also be observed by driving the vehicle. POINTS IN WAVEFORM MEASUREMENT NOTE: The wheel speed sensor cable moves in relation to motion of the front or rear suspension. Therefore, it is likely that it has an open circuit only when driving on rough roads but it functions normally when driving on smooth roads. It is recommended to observe sensor output voltage waveform also under special conditions, such as driving on a rough road. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 3519 Wheel Speed Sensor: Service and Repair REMOVAL AND-INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 3520 The clearance between the wheel speed sensor and the ABS rotor's toothed surface is not adjustable, but measure the distance between the sensor installation surface and the ABS rotor's toothed surface. Standard value: 28.2 - 28.5 mm (1.11 - 1.12 inches) INSPECTION SPEED SENSOR CHECK 1. Check whether any metallic foreign material has adhered to the projection at the speed sensor tip. Remove any foreign material. Also check whether the pole piece is damaged. Replace it with a new one if it is damaged. NOTE: The projection can become magnetized due to the magnet inside the speed sensor, causing foreign material to easily adhere to it. The projection may not be able to correctly sense the wheel rotation speed if foreign matter is on it or if it is damaged. 2. Measure the resistance between the speed sensor terminals. Standard value: 1.28 - 1.92 k Ohms 3. If the internal resistance of the speed sensor is not within the standard value' replace it with a new speed sensor. 4. Remove all connections from the speed sensor. The circuit should be open between terminals (1) and (2) and the body of the speed sensor. If the circuit is not open, replace with a new speed sensor. 5 Check the speed sensor cable for breakage, damage or disconnection. Replace with a new one if a problem is found NOTE: When checking for cable damage, remove the cable clamp part from the body and then gently bend and pull the cable near the clamp. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 3521 TOOTHED ABS ROTOR CHECK Check whether the ABS rotor teeth are broken or deformed. Replace the driveshaft assembly for the front side or the ABS rotor for the rear side, respectively, if the teeth are damaged or deformed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair CAUTION: Use only brake fluid DOT 3 or DOT 4. Never mix the specified brake fluid with other fluid as it will influence the braking performance significantly. MASTER CYLINDER BLEEDING The master cylinder has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.) 1. Fill the reserve tank with brake fluid. 2. Keep the brake pedal depressed. 3. Have another person cover the master cylinder outlet with a finger. 4. With the outlet still closed, release the brake pedal. 5. Repeat steps 2 - 4 three or four times to fill the inside of the master cylinder with brake fluid. BRAKE LINE BLEEDING CAUTION: For vehicles equipped with ABS, be sure to filter/strain the brake fluid being added to the master cylinder reservoir tank. Debris may damage the hydraulic unit. Start the engine and bleed the air in the sequence shown in the figure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Pedal support member mounting bolt ................................................................................................................................... 12 ± 2 Nm (102 ± 22 inch lbs.) Pedal support member mounting nut .................................................................................................................................... 14 ± 3 Nm (124 ± 26 inch lbs.) Brake pedal height ....................................................................................................... ........................................................... 175 - 178 mm (6.9 - 7.0 inch) Brake pedal free play ............... ................................................................................................................................................... 3 - 8 mm (0.12 - 0.31 inch) Brake pedal to floor board clearance ............................................................................................................................................. 90 mm (3.5 inch) or more Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions Brake Pedal Assy: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3530 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3531 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3536 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 Brake Pedal Assy: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3539 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page 3552 Brake Pedal Assy: Testing and Inspection BRAKE PEDAL CHECK AND ADJUSTMENT BRAKE PEDAL HEIGHT 1. Turn up the carpet etc. under the brake pedal. 2. Measure the brake pedal height as illustrated. If it is not within the standard value, adjust as follows. Standard value: 175 - 178 mm (6.9 - 7.0 inches) [From the surface of melting sheet (floorboard) to the face of pedal pad] 1) Disconnect the stoplight switch connector. 2) Rotate the stoplight switch 1/4 turn counterclockwise to loosen. 3) Loosen the operating rod jam nut. Turn the serrations of the operation rod with pliers to adjust the brake pedal height to the standard valve. 4) Turn the stoplight switch until it's thread part contacts the stopper. During this step, secure the pedal by moving it forward by hand. 5) Turn the stoplight switch 1/4 turn clockwise to secure. Then confirm that the clearance between the switch plunger and the stopper is as shown. 6) Connect the connector of the stoplight switch. 7) Check to be sure that the stoplight does not illuminate with the brake pedal released 3. Return the carpet, etc. to its original position. BRAKE PEDAL FREE PLAY 1. Turn the ignition switch to the "LOCK" (OFF) position, depress the brake pedal two or three times. After eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is within the standard value range. Standard value: 3 - 8 mm (0.12 0.31 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page 3553 2. If the brake pedal play is not within the standard value, check the followings, and adjust or replace if necessary: ^ Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod ^ Brake pedal height ^ Installation position of the stoplight switch, etc. CLEARANCE BETWEEN BRAKE PEDAL AND FLOORBOARD 1. Turn up the carpet etc. under the brake pedal. 2. Start the engine, depress the brake pedal with approximately 490 N (110 pound) of force, and measure the clearance between the brake pedal and the floorboard. 90 mm (3.5 inches) or more [From the surface of melting sheet (floorboard) to the face of pedal pad] 3. If the clearance is outside the standard value, check for air trapped in the brake line and thickness of the disc brake pad. And then adjust and replace defective parts as required. 4. Return the carpet etc. to its original position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page 3554 Brake Pedal Assy: Service and Repair REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 Brake Warning Indicator: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3577 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3578 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3579 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3580 Brake Warning Indicator: Electrical Diagrams Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 3581 Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front disc brake wheel cylinder ID ........................................................................................................................................................ 60.3 mm (2.37 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Disc brake pad thickness Standard Value .................................................................................................................................... ................................................ 10.0 mm (0.4 inch) Limit ..................................................................... ............................................................................................................... Minimum 2.0 mm (0.08 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 3589 Brake Pad: Service and Repair DISC BRAKE PAD CHECK AND REPLACEMENT NOTE: The brake pads have indicators that contact the brake disc when the brake pad thickness becomes 2 mm (0.08 inch), and emit a squealing sound to warn the driver. CAUTION: ^ Whenever a pad must be replaced, replace both LH and RH wheel pads as a set to prevent the vehicle from pulling to one side when braking. ^ If there is a significant difference in the thicknesses of the pads on the left and right sides, check the sliding condition of the piston, lock pin and guide pin. 1. Check the brake pad thickness through the caliper body check port Standard value: 10.0 mm (0.39 inch) Minimum limit: 2.0 mm (0.08 inch) CAUTION: Do not wipe the special grease from the guide pin. Do not contaminate the guide pin. 2. Remove the guide pin. Lift the caliper assembly and secure it with a wire. 3. Remove the following parts from caliper support. 1) Pad and wear indicator assembly 2) Inner shim B 3) Inner shim A 4) Pad assembly Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 3590 5) Outer shim B 6) Outer shim A 7) Clip 4. Remove the following parts from caliper support. 1) Pad and wear indicator assembly 2) Inner shim B 3) Inner shim A 4) Pad assembly 5) Outer shim 6) Clip 5. Measure the hub torque before and after pad installation. CAUTION: Do not apply excessive grease. Excessive grease may cause brake performance to become poor. 6. For front disc brake and rear disc bake, apply brake grease MOPAR Multi-purpose Grease Part No.2932524 or equivalent to the following positions before installing the pad. ^ Pad and wear indicator assembly and inner shim A contact surface ^ Inner shim A and inner shim B contact surface ^ Pad assembly and outer shim A contact surface ^ Outer shim A and inner shim B contact surface ^ Pad and wear indicator assembly and inner shim A contact surface ^ Inner shim A and inner shim B contact surface 7. Install the pad and caliper assembly, and check the brake drag force. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front disc brake disc effective diameter ................................................................................................................................................... 204 mm (8.0 inch) Disc brake disc thickness Standard Value .................................................................................................................................... ................................................ 24.0 mm (0.9 inch) Limit ..................................................................... ............................................................................................................. Minimum 22.4 mm (0.88 inch) Disc brake disc run-out ........................................................................................................................ ................................................ 0.06 mm (0.002 inch) Front disc brake drag force .............................. ..................................................................................................................................... 69 N (16 lbs.) or less Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Disc Brake Rotor Check Brake Rotor/Disc: Testing and Inspection Disc Brake Rotor Check DISC BRAKE ROTOR CHECK CAUTION: Disc brakes must be kept within the allowable service values in order to maintain normal brake operation. Before turning the brake disc, the conditions should be checked. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Disc Brake Rotor Check > Page 3596 Brake Rotor/Disc: Testing and Inspection Brake Disc Run-Out Check and Correction Front Disc Brake Run-Out Check and Correction FRONT DISC BRAKE RUN-OUT CHECK AND CORRECTION 1. Remove the caliper support; then raise the caliper assembly upward and secure it with a wire. 2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust. 3. Place a dial gauge approximately 5 mm (0.2 inch) from the outer circumference of the brake disc, and measure the runout of the disc. Limit: 0.06 mm (0.002 inch) 4. If the run-out of the brake disc is limit value or more, turn rotor with an on-car type brake lathe ("Accuturn-8750" or equivalent). If it still exceeds the limit, inspect hub end play. Limit: 0.05 mm (0.002 inch) 5. If the play exceeds the limit, check the hub. If the play does not exceed the limit, replace the brake disc. Rear Disc Brake Run-Out Check and Correction REAR DISC BRAKE RUN-OUT CHECK AND CORRECTION 1. Remove the caliper support; then raise the caliper assembly upward and secure it with a wire. 2. Check the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust. 3. Place a dial gauge approximately 5 mm (0.2 inch) from the outer circumference of the brake disc, and measure the runout of the disc. Limit: 0.08 mm (0.003 inch) 4. If the runout of the brake disc is the limit value or more, change the phase of the disc and hub, and then measure the run-out again. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Disc Brake Rotor Check > Page 3597 1) Before removing the brake disc, place a mating mark on both the wheel stud and disc with chalk where the run-out is greatest. 2) Place a dial gauge as shown in the illustration, and then move the hub in the axial direction and measure the play. Limit: 0.05 mm (0.002 inch) 3) If the play does not exceed the limit install the brake disc at a different phase, and then check the run-out of the brake disc again. 5. If the run-out cannot be corrected by changing the phase of the brake disc, replace the disc. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Disc Brake Rotor Check > Page 3598 Brake Rotor/Disc: Testing and Inspection Brake Disc Thickness Check BRAKE DISC THICKNESS CHECK 1. Remove dirt and rust from the brake disc surface. 2. Using a micrometer, measure disc thickness at eight positions, approximately 45 degrees apart and 10 mm (0.4 inch) in from the outer edge of the disc. Standard value: 24.0 mm (0.9 inch) Minimum limit: 22.4 mm (0.88 inch) NOTE: Thickness variation (at least 8 positions) should not be more than 0.015 mm (0.0006 inch). 3. If the disc thickness is less than 22.4 mm (0.88 inch) thick, replace it with a new one. If thickness variation exceeds the specification, turn rotor with an on-the-car type brake lathe ("Accuturn-8750" or equivalent). If the calculated final thickness after turning the rotor is less than the standard value, replace the disc. 1. Remove dirt and rust from the brake disc surface. 2. Measure the disc thickness at four positions or more. Standard value: 10.0 mm (0.4 inch) Minimum limit: 8.4 mm (0.33 inch) 3. Thickness variations (at least 4 positions) should not be more than 0.015 mm (0.0006 inch). 4. If the disc is thickness than 8.4 mm (0.33 inch) thick, replace it with a new one. If thickness variation exceeds the specification, turn rotor with an on-the-car brake lathe ("Accuturn-8750" or equivalent). If the calculated final thickness is less than the standard value, replace the disc. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection AUTO ADJUSTER FUNCTION CHECK 1. Remove the brake drum. 2. Operate the parking brake lever. Observe adjuster lever movement for ratcheting action of the auto adjuster. Repair or replace the lever(s) as required. 3. Remove the shoe-to-lever spring. 4. Remove the adjuster. NOTE: It may be necessary to rotate the adjuster wheel bottom to top to release tension. 5. Inspect the adjuster wheel for wear, i.e., flat spots, worn teeth, etc. Replace if faulty. 6. Check both ends of the adjuster for smooth rotation. Replace if faulty. 7. Apply brake grease MOPAR Multi-mileage Lubrication Part No.2525035 or equivalent as shown. 8. To install the adjuster, assemble the adjuster so it is at its minimum length and insert between shoe and lining assemblies. 9. Install the adjuster lever and shoe-to-lever spring. 10. Rotate the adjuster wheel top to bottom until the drum has a slight drag when the drum is installed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear drum brake drum ID .................................................................................................................... ................................................. 228.6 mm (9.0 inch) Rear drum inside diameter Standard Value .................................................................................................................................... ............................................ 228.6 mm (9.00 inch) Limit ..................................................................... ........................................................................................................................... 230.6 mm (9.08 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Inside Diameter Check Vehicle with Drum Brakes Brake Drum: Testing and Inspection Brake Drum Inside Diameter Check Vehicle with Drum Brakes BRAKE DRUM INSIDE DIAMETER CHECK 1. Remove the brake drum. 2. Measure the inside diameter of the brake drum at two or more locations. Standard value: 228.6 mm (9.00 inches) Limit: 230.6 mm (9.08 inches) 3. Replace the brake drums, shoe and lining assembly when wear exceeds the limit value or is badly imbalanced. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Inside Diameter Check Vehicle with Drum Brakes > Page 3608 Brake Drum: Testing and Inspection Brake Lining and Drum Contact Check BRAKE LINING AND BRAKE DRUM CONTACT CHECK 1. Remove the brake drum. 2. Remove the shoe and lining assembly. 3. Chalk the inner surface of the brake drum and rub with the shoe and lining assembly. 4. Replace the shoe and lining assembly or brake drums if there are any irregular contact areas. NOTE: Clean off chalk after check. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Inside Diameter Check Vehicle with Drum Brakes > Page 3609 Brake Drum: Testing and Inspection Rear Brake Disc Inside Diameter Check BRAKE DRUM INSIDE DIAMETER CHECK 1. Remove the rear brake assembly, raise the rear brake assembly and secure it with a wire, etc. 2. Remove the brake disc. 3. Measure the inside diameter of the hub and disc at two or more locations. Standard value: 168.0 mm (6.61 inches) Limit: 169.0 mm (6.65 inches) 4. Replace the brake discs and shoe and lining assembly when the wear exceeds the limit value or if the measured areas are not equal to each other. (concentric). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Rear drum brake lining thickness Standard Value .................................................................................................................................... ................................................ 4.9 mm (0.19 inch) Limit ..................................................................... ............................................................................................................... Minimum 1.0 mm (0.04 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 3613 Brake Shoe: Testing and Inspection BRAKE LINING THICKNESS CHECK CAUTION CAUTION: ^ Whenever the shoe and lining assembly is replaced, replace both RH and LH assemblies as a set to prevent the car from pulling to one side when braking. ^ If there is a significant difference in the thickness of the shoe and lining assemblies on the left and right sides, check the sliding condition of the piston. NOTE: For brake lining thickness for drum-in-disc brake, refer to Parking Brake Drum. 1. Remove the brake drum. 2. Measure the thickness of the brake lining at the area with the worst wear. Standard value: 4.9 mm (0.19 inch) Minimum limit: 1.0 mm (0.04 inch) 3. Replace the shoe and lining assembly if the brake lining thickness is less than the limit or if it is not worn evenly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Rear drum brake wheel cylinder ID ..................................................................................................................................................... 19.05 mm (0.75 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair CAUTION: Use only brake fluid DOT 3 or DOT 4. Never mix the specified brake fluid with other fluid as it will influence the braking performance significantly. MASTER CYLINDER BLEEDING The master cylinder has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.) 1. Fill the reserve tank with brake fluid. 2. Keep the brake pedal depressed. 3. Have another person cover the master cylinder outlet with a finger. 4. With the outlet still closed, release the brake pedal. 5. Repeat steps 2 - 4 three or four times to fill the inside of the master cylinder with brake fluid. BRAKE LINE BLEEDING CAUTION: For vehicles equipped with ABS, be sure to filter/strain the brake fluid being added to the master cylinder reservoir tank. Debris may damage the hydraulic unit. Start the engine and bleed the air in the sequence shown in the figure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front disc brake wheel cylinder ID ........................................................................................................................................................ 60.3 mm (2.37 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Fill to the Full mark on the brake fluid reservoir. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 3628 Brake Fluid: Fluid Type Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 * If DOT 3 brake fluid is not available, DOT 4 or DOT 4+ is acceptable. Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection BRAKE FLUID LEVEL SENSOR CHECK The brake fluid level sensor is in good condition if there is no continuity when the float surface is above "A" and if there is continuity when the float surface is below "A." Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake tube flare nut ............................................................................................................................. ......................................... 15 ± 2 Nm (11 ± 1 ft. lbs.) Brake hose connector bolt ............................................................................................................................................................ 30 ± 4 Nm (22 ± 3 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Proportioning valve output fluid pressure Split point ............................................................................................................................................. ............................... 2.7 - 3.2 mm (391 - 462 inch) When input fluid pressure is 9.8 MPa (1,422 psi). .............................................................................................................. 4.3 - 5.1 mm (619 - 732 inch) Proportioning valve output fluid pressure difference between left and right ............................................................................................... 0.4 MPa (57 psi) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 3638 Brake Proportioning/Combination Valve: Testing and Inspection PROPORTIONING VALVE FUNCTION TEST 1. Connect two pressure gauges, one each to the input side and output side of the proportioning valve, as shown. 2. Air bleed the brake line and the pressure gauge. 3. While gradually depressing the brake pedal, make the following measurements and check to be sure that the measured values are within the allowable range. 1) Output fluid pressure begins to drop relative to input fluid pressure (split point). Standard value: 2.7 - 3.2 MPa (391 - 462 psi) 2) Check that the output fluid pressure is at standard value when the input fluid pressure indicates 9.8 MPa (1,422 psi). Standard value: 4.3 - 5.1 MPa (619 - 732 psi) 3) Output fluid pressure difference between left and right brake lines. Limit: 0.4 MPa (57 psi) 4. If the measured fluid pressures are not within allowable ranges, replace the proportioning valve. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 3639 Brake Proportioning/Combination Valve: Service and Repair REMOVAL AND INSTALLATION INSTALLATION SERVICE POINT >>A<< BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit as shown in the illustration. 1. Proportioning valve - Rear brake (LH) 2. Proportioning valve - Rear brake (RH) 3. Proportioning valve - Front brake (RH) 4. Proportioning valve - Front brake (LH) 5. Proportioning valve - Master cylinder (secondary) 6. Proportioning valve - Master cylinder (primary) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake tube flare nut ............................................................................................................................. ......................................... 15 ± 2 Nm (11 ± 1 ft. lbs.) Hydraulic unit bracket bolt ........................................................................................................................................................... 30 ± 5 Nm (22 ± 4 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 3643 Hydraulic Control Assembly - Antilock Brakes: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Testing and Inspection > Anti-Lock Braking System (ABS) Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection Anti-Lock Braking System (ABS) HYDRAULIC UNIT CHECK Required Special Tool: ^ MB991502: Scan Tool (MUT-II) CAUTION: ^ The roller of the braking force tester and the tire should be dry during testing. ^ When testing the front brakes, apply the parking brake. When testing the rear brakes, stop the front wheels with chocks. 1. Jack up the vehicle. Then support the vehicle with rigid racks at the specified jack-up points or place the front or rear wheels on the rollers of the braking force tester. 2. Release the parking brake, and feel the drag force (drag torque) on each road wheel. When using the braking force tester, take a reading of the brake drag force. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Testing and Inspection > Anti-Lock Braking System (ABS) > Page 3646 8. After inspection, disconnect the scan tool immediately after turning the ignition switch to the "LOCK" (OFF) position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Testing and Inspection > Anti-Lock Braking System (ABS) > Page 3647 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection Traction Control System (TCL) HYDRAULIC UNIT CHECK Required Special Tool: ^ MB991502: Scan Tool CAUTION: ^ The roller of the braking force tester and the tire should be dry during testing. ^ When testing the front brakes, apply the parking brake. When testing the rear brakes, stop the front wheels with chocks. 1. Jack-up the vehicle. Then support the vehicle with rigid racks at the specified jack-up points or place the front or rear wheels on the rollers of the braking force tester. 2. Release the parking brake, and feel the drag force (drag torque) on each road wheel. When using the braking force tester, take a reading of the brake drag force. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 3. Turn the ignition switch to the "LOCK" (OFF) position and set scan tool MB991502 as shown in the illustration. 4. After checking that the shift lever/selector lever is in neutral, start the engine. 5 Use scan tool MB991502 to force-drive the actuator. NOTE: The TCL system will switch to the scan tool mode and the ABS warning light will illuminate. NOTE: When the TCL has been interrupted by the fail-safe function, scan too/ MB991502 actuator testing cannot be used. 6. Turn the wheel by hand and check the change in braking force; Use a braking force tester. The braking force reading value should change when the actuator test is carried out. The result should be as shown in the diagram above. 7. If the result of inspection is abnormal, replace the hydraulic unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Testing and Inspection > Page 3648 Hydraulic Control Assembly - Antilock Brakes: Service and Repair HYDRAULIC UNIT REMOVAL AND INSTALLATION NOTE: The ABS-ECU is integrated in the hydraulic unit. REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Testing and Inspection > Page 3649 INSTALLATION SERVICE POINT >>A<< BRAKE TUBE INSTALLATION Connect the tubes to the hydraulic unit as shown in the illustration. 1. To the proportioning valve (rear brake: LH) 2. To the proportioning valve (rear brake: RH) 3. From the master cylinder (primary) 4. From the master cylinder (secondary) 5. To the front brake (RH) 6. To the front brake (LH) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Fitting ................................................................................................................................................... ........................................ 17 ± 1 Nm (12 ± 1 ft. lbs.) Master cylinder mounting nut ............................................................................................................................................... 13 ± 2 Nm (111 ± 22 inch lbs.) Master cylinder ID ......................................................................................... ........................................................................................ 27.0 mm (1.06 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Diagrams > Basic Brake System Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Diagrams > Basic Brake System > Page 3655 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Diagrams > Page 3656 Brake Master Cylinder: Testing and Inspection MASTER CYLINDER FUNCTION CHECK 1. Remove the reservoir cap and diaphragm. 2. While watching the open reservoir from a distance of 50 cm (20 inches), have an assistant depress the brake pedal. If there was a stream of brake fluid rising from the reservoir, proceed to Step 3. If there was no stream of brake fluid rising from the reservoir, repair or replace the master cylinder. 3. While watching the open reservoir from a distance of 50 cm (20 inches), have the assistant release the brake pedal. If there was a small amount of air bubbles rising through the brake fluid, master cylinder function is normal. If there was no bubble rising through the brake fluid, repair or replace the master cylinder. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Removal and Installation Brake Master Cylinder: Service and Repair Master Cylinder Removal and Installation REMOVAL AND INSTALLATION CAUTION: Do not remove the check valve from the vacuum hose. If the check valve is defective, replace it together with the vacuum hose. INSTALLATION SERVICE POINTS >>A<< VACUUM HOSE CONNECTION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Removal and Installation > Page 3659 1. Install the vacuum hose with the white-marked sections facing up. 2. Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure with the hose clamp. >>B<< CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSHROD AND PRIMARY PISTON 1. Using a hand vacuum pump, apply a negative pressure of -66.7 kPa (19.6 inHg) to the brake booster. 2. Measure protruding length A at the pushrod. Standard value (A): 10.28 - 10.53 mm (0.404 - 0.415 inch) 3. If the protruding length is not within the standard value range, adjust by changing the pushrod length by turning the end of the pushrod. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Removal and Installation > Page 3660 Brake Master Cylinder: Service and Repair Master Cylinder Disassembly and Assembly Basic Brake System DISASSEMBLY AND ASSEMBLY CAUTION: Do not disassemble the primary piston and secondary piston assembly. DISASSEMBLY SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Removal and Installation > Page 3661 ^ Check the diaphragm for cracks and wear. Anti-Lock Braking System (ABS) DISASSEMBLY AND ASSEMBLY CAUTION: Do not disassemble the primary and secondary piston assemblies. DISASSEMBLY SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Rear drum brake wheel cylinder ID ..................................................................................................................................................... 19.05 mm (0.75 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Specifications Parking Brake Backing Plate: Specifications Knuckle to backing plate bolt ...................................................................................................................................................... 71 ± 7 Nm (53 ± 5 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams Parking Brake Cable: Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3672 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3673 Parking Brake Cable: Service and Repair REMOVAL AND INSTALLMENT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3674 REMOVAL AND INSTALLATION REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Diagrams > Page 3675 Extend the shoe and lining assembly, and remove the shoe hold-down cup. INSTALLATION SERVICE POINTS >>A<< ADJUSTER INSTALLATION Install the adjuster so that the shoe adjusting bolt of left hand wheel is attached towards the front of the vehicle, and the shoe adjusting bolt of right hand wheel is towards the rear of the vehicle. >>B<< SHOE-TO-ANCHOR SPRING INSTALLATION CAUTION: The load on the respective shoe-to-anchor springs is different, so the rear side spring in the figure has been painted. Install the shoe-to-anchor springs in the order shown in the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Caliper > Component Information > Specifications Parking Brake Caliper: Specifications Brake caliper assembly ....................................................................................................................... ......................................... 60 ± 5 Nm (45 ± 3 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications Parking Brake Drum: Specifications Brake drum inside diameter Standard Value .................................................................................................................................... ............................................ 168.0 mm (6.61 inch) Limit ..................................................................... ........................................................................................................................... 169.0 mm (6.65 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications > Page 3682 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications > Page 3683 Parking Brake Drum: Testing and Inspection BRAKE LINING AND BRAKE DRUM CHECK 1. Measure the thickness of the brake lining at several places. Standard value: 2.8 mm (0.11 inch) Minimum limit: 1.0 mm (0.04 inch) 2. If the thickness of the brake lining is below the limit, replace the shoe and lining assemblies on both sides of the vehicle. Never replace only one side. 3. Measure the inside diameter of the brake disc in two places or more. Standard value: 168.0 mm (6.61 inch) Limit: 169.0 mm (6.65 inch) 4. If the inside diameter exceeds the limit, or if it is excessively worn on one side, replace the brake disc. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Drum > Component Information > Specifications > Page 3684 Parking Brake Drum: Service and Repair REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications Parking Brake Lever: Specifications Parking brake lever stroke drum brake .......................................................................................................................................... ........................................................... 5 - 7 notches Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3688 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3689 Parking Brake Lever: Testing and Inspection PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 1. Pull the parking brake lever with a force of approximately 196 N (44 pounds) and count the number of notches. Standard value: 5 - 7 notches 3 - 5 notches 2. If the parking brake lever stroke is not the standard value, adjust. Remove the floor console cup tray or arm rest assembly, loosen the adjusting nut as far as the end of the cable rod to release the cable. 3. For vehicles with drum brake, start the engine. Depress the brake pedal repeatedly until the stroke no longer changes. NOTE: Depressing the brake pedal repeatedly will automatically adjust the shoe clearance to the normal setting. 4. For vehicles with drum-in-disc brake, remove the adjustment hole plug, and then use a flat-tip screwdriver to turn the adjuster in the direction of the arrow (the direction which expands the shoe) so that the disc will not rotate. Return the adjuster five notches in the direction opposite to the direction of the arrow. CAUTION: If the parking brake lever stroke is below the standard value and the braking is too firm, the rear brakes may drag. 5 Turn the adjusting nut to adjust the parking brake lever stroke to the standard value. After adjusting, check that there is no space between the adjusting nut and the parking brake lever. 6. After adjusting the parking brake lever stroke, jack up the rear of the vehicle. Release the parking brake and turn the rear wheels to check that the rear brakes are not dragging. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Specifications > Page 3690 Parking Brake Lever: Service and Repair REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Testing and Inspection Parking Brake Release Switch: Testing and Inspection PARKING BRAKE, SWITCH CHECK 1. Remove the floor console. 2. Check for continuity between the parking brake switch terminal and the switch mounting bolt. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Diagrams > Page 3697 Parking Brake Shoe: Testing and Inspection BRAKE LINING AND BRAKE DRUM CHECK 1. Measure the thickness of the brake lining at several places. Standard value: 2.8 mm (0.11 inch) Minimum limit: 1.0 mm (0.04 inch) 2. If the thickness of the brake lining is below the limit, replace the shoe and lining assemblies on both sides of the vehicle. Never replace only one side. 3. Measure the inside diameter of the brake disc in two places or more. Standard value: 168.0 mm (6.61 inch) Limit: 169.0 mm (6.65 inch) 4. If the inside diameter exceeds the limit, or if it is excessively worn on one side, replace the brake disc. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Lining Running-In Parking Brake Shoe: Service and Repair Lining Running-In LINING RUNNING-IN CAUTION: Carry out running-in a place with good visibility, and pay careful attention to safety. Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when brake performance is insufficient. 1. Adjust the parking brake stroke to the specified value. 2. Hook a spring scale onto the center of the parking brake lever grip and pull it with a force of 98 - 147 N (22 - 33 pounds) in a direction perpendicular to the handle. 3. Drive the vehicle at a constant speed of 35 - 50 km/h (22 - 31 mph) for 100 meters (328 feet). 4. Release the parking brake and let the brakes cool for five to ten minutes. 5 Repeat the procedure in steps 2 to 4 four to five times. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Lining Running-In > Page 3700 Parking Brake Shoe: Service and Repair Removal and Installation REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Brake booster mounting nut .................................................................................................................................................. 14 ± 3 Nm (124 ± 26 inch lbs.) Brake booster effective diameter of power cylinder .................................................................................................................... 205 + 230 mm (8 + 9 inch) Brake booster boosting ratio ....................................................................................................... ...................................................................................... 7.0 Brake booster push rod protruding length ................................................................................................................. 10.28 - 10.53 mm (0.404 - 0.415 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 3705 Vacuum Brake Booster: Testing and Inspection BRAKE BOOSTER OPERATING TEST For simple checking of the brake booster operation, carry out the following tests: 1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly. If the pedal height remains unchanged, the booster is defective. Go to Step 2. 2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective. Go to Step 3. 3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. If the above three tests are okay, the booster is OK. If one of the above three tests is not okay, the check valve, vacuum hose, or booster is defective. Check the check valve, vacuum hose for leaks, high volume engine vacuum applied to booster. Repair or replace as necessary. If OK, replace booster and repeat this test starting at Step 1. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 3706 Vacuum Brake Booster: Service and Repair REMOVAL AND INSTALLATION CAUTION: Do not remove the check valve from the vacuum hose. If the check valve is defective, replace it together with the vacuum hose. INSTALLATION SERVICE POINTS >>A<< VACUUM HOSE CONNECTION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 3707 1. Install the vacuum hose with the white-marked sections facing up. 2. Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure with the hose clamp. >>B<< CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSHROD AND PRIMARY PISTON 1. Using a hand vacuum pump, apply a negative pressure of -66.7 kPa (19.6 inHg) to the brake booster. 2. Measure protruding length A at the pushrod. Standard value (A): 10.28 - 10.53 mm (0.404 - 0.415 inch) 3. If the protruding length is not within the standard value range, adjust by changing the pushrod length by turning the end of the pushrod. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection CHECK VALVE OPERATION CHECK CAUTION: The check valve should not be removed from the vacuum hose. 1. Remove the vacuum hose. CAUTION: If the check valve is defective, replace it as an assembly unit together with the vacuum hose. 2. Check the operation of the check valve by using a vacuum pump. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Overall View View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Testing and Inspection Brake Fluid Level Sensor/Switch: Testing and Inspection BRAKE FLUID LEVEL SENSOR CHECK The brake fluid level sensor is in good condition if there is no continuity when the float surface is above "A" and if there is continuity when the float surface is below "A." Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Testing and Inspection Parking Brake Release Switch: Testing and Inspection PARKING BRAKE, SWITCH CHECK 1. Remove the floor console. 2. Check for continuity between the parking brake switch terminal and the switch mounting bolt. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Wheel speed sensor internal resistance .................................................................................................................................................... 1.28 - 1.92 k Ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 3726 Wheel Speed Sensor: Mechanical Specifications Distance between wheel speed sensor installation surface and ABS rotor tooth top; 28.2 - 28.5 mm (1.11 - 1.12 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 3727 Wheel Speed Sensor: Locations View c Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 3728 View d Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 3729 Wheel Speed Sensor: Testing and Inspection WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT Required Special Tool ^ MB991219: Inspection Harness 1. Lift up the vehicle, and release the parking brake. 2. Disconnect the ABS DECO connector A-02, and then use special tool MB991219 to measure the output voltage at the harness side connector. 3. Manually turn the wheel to be measured 112 to 1 burnt second. Measure the output voltage with a voltmeter or oscilloscope. Output voltage: ^ Minimal voltmeter reading: 42 mV ^ Maximum voltmeter reading: 300 mV ^ Minimal oscilloscope reading: 120 mV ^ Maximum oscilloscope reading: 600 mV Probable causes of low output voltage ^ Wheel speed sensor pole piece-to-ABS rotor clearance too large ^ Faulty wheel speed sensor NOTE: Check the connection of the sensor harness and connector before using the oscilloscope. 4. To observe the waveform with an oscilloscope: ^ Front Wheels: Shift into low gear and drive the wheels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 3730 ^ Rear Wheels: Turn the wheels manually at a constant speed NOTE: The output waveform is low when the wheel speed is low. Similarly, it will be higher as the wheel speed increases. Waveform may also be observed by driving the vehicle. POINTS IN WAVEFORM MEASUREMENT NOTE: The wheel speed sensor cable moves in relation to motion of the front or rear suspension. Therefore, it is likely that it has an open circuit only when driving on rough roads but it functions normally when driving on smooth roads. It is recommended to observe sensor output voltage waveform also under special conditions, such as driving on a rough road. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 3731 Wheel Speed Sensor: Service and Repair REMOVAL AND-INSTALLATION REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 3732 The clearance between the wheel speed sensor and the ABS rotor's toothed surface is not adjustable, but measure the distance between the sensor installation surface and the ABS rotor's toothed surface. Standard value: 28.2 - 28.5 mm (1.11 - 1.12 inches) INSPECTION SPEED SENSOR CHECK 1. Check whether any metallic foreign material has adhered to the projection at the speed sensor tip. Remove any foreign material. Also check whether the pole piece is damaged. Replace it with a new one if it is damaged. NOTE: The projection can become magnetized due to the magnet inside the speed sensor, causing foreign material to easily adhere to it. The projection may not be able to correctly sense the wheel rotation speed if foreign matter is on it or if it is damaged. 2. Measure the resistance between the speed sensor terminals. Standard value: 1.28 - 1.92 k Ohms 3. If the internal resistance of the speed sensor is not within the standard value' replace it with a new speed sensor. 4. Remove all connections from the speed sensor. The circuit should be open between terminals (1) and (2) and the body of the speed sensor. If the circuit is not open, replace with a new speed sensor. 5 Check the speed sensor cable for breakage, damage or disconnection. Replace with a new one if a problem is found NOTE: When checking for cable damage, remove the cable clamp part from the body and then gently bend and pull the cable near the clamp. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 3733 TOOTHED ABS ROTOR CHECK Check whether the ABS rotor teeth are broken or deformed. Replace the driveshaft assembly for the front side or the ABS rotor for the rear side, respectively, if the teeth are damaged or deformed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Overall View View P Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3741 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3742 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3743 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3744 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3745 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3746 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3747 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 Neutral Safety Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3750 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3751 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3752 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3753 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3754 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3755 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3756 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 3762 Neutral Safety Switch: Testing and Inspection PARK/NEUTRAL POSITION SWITCH CONTINUITY CHECK PARK/NEUTRAL POSITION SWITCH CONTINUITY CHECK Part 1 of 2 Part 2 of 2 NOTE: For vehicles with sport mode, four positions (P, R, N, D) are used. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 3763 Neutral Safety Switch: Adjustments PARK/NEUTRAL POSITION SWITCH AND CONTROL CABLE ADJUSTMENT 1. Set the selector lever to the "N" position. 2. Loosen the control cable to the manual control lever coupling nut to free the cable and lever. 3. Set the manual control lever to the neutral position. 4. Loosen the park/neutral position switch body mounting bolts and turn the park/neutral position switch body so the hole in the end of the manual control lever and the hole (section A - A in the figure on the left) in the flange of the park/neutral position switch body flange are aligned. NOTE: The park/neutral position switch body can be aligned by inserting a 5-mm diameter steel bar into the end hole of the manual control lever and the flange hole of the park/neutral position switch body. 5. Tighten the park/neutral position switch body mounting bolts to the specified torque. Be careful at this time that the switch body does not move. Tightening torque:...............11 ± 1 Nm (96 ± 8 inch lbs.) 6. Gently push the transaxle control cable in the direction of the arrow, until the cable is taut. Tighten the adjusting nut. Tightening torque:.................12 ± 2 Nm (107 ± 17 inch lbs.) 7. Check that the selector lever is in the "N" position. 8. Check that each position of the manual control lever matches each position of the selector lever and using scan tool. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions Starter Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 Starter Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3778 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3779 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3780 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3781 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3782 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3783 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3784 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3788 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3789 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3790 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Diagrams > Page 3791 Starter Relay: Service and Repair Starter Relay Check STARTER RELAY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Locations > Fusible Link, Fuse and IOD or Storage Connector Battery: Locations Fusible Link, Fuse and IOD or Storage Connector Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Locations > Fusible Link, Fuse and IOD or Storage Connector > Page 3796 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Locations > Fusible Link, Fuse and IOD or Storage Connector > Page 3797 Battery: Locations Inspection Terminal Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Locations > Fusible Link, Fuse and IOD or Storage Connector > Page 3798 Battery: Locations Grounding Grounding Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Locations > Fusible Link, Fuse and IOD or Storage Connector > Page 3799 Over All Views 1-15 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Locations > Fusible Link, Fuse and IOD or Storage Connector > Page 3800 Battery: Locations Control Unit Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions Battery: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Battery: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Page 3824 Battery: Testing and Inspection BATTERY TESTING PROCEDURE STEP 1. Check the battery cables. Remove the negative cable, then the positive cable. Check for dirty or corroded connections. Q: Are the battery cables dirty or have corroded connections? YES: Clean the battery cables. Then go to Step 2. NO: Go to Step 2. STEP 2. Check the battery post. Check for loose battery post. Q: Are the battery post faulty? YES: Replace the battery. Then go to Step 4. NO: Go to Step 3. STEP 3. Check the battery case and cover. 1. Remove the hold-downs and shields. 2. Check for broken/cracked case or cover. Q: Is the battery case or cover faulty? YES: Replace the battery. Then go to Step 4. NO: Go to Step 4. STEP 4. Check the open circuit voltage. 1. Turn the headlights on for 15 seconds. 2. Turn the headlights off for two minutes to allow battery positive voltage to stabilize. 3. Disconnect the battery cables. 4. Read open circuit voltage. Q: Is open circuit voltage 12.4 volts or more? NO: Go to Step 6. YES: Go to Step 5. STEP 5. Charge the battery. Q: Charging the battery? YES: Replace the battery. Then reset the battery, and then go to Step 4. NO: Charge the battery at 5 amps for 15 hours. Then re-test the battery, and then go to Step 4. STEP 6. Check the load test. 1. Connect a load tester to the battery. Load Test Rate Chart 2. Load the battery at the recommended discharge rate for 15 seconds. 3. Read voltage after 15 seconds, then remove load. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Diagrams > Page 3825 Load Test Chart 4. Compare the measured value with the minimum voltage. Q: Is the voltage higher than minimum voltage? NO: Replace the battery. Then go to Step 4. YES: The battery is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Procedures Battery: Procedures Battery Cleaning and Inspection BATTERY CHECK WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. BATTERY VISUAL INSPECTION (1) The battery contains a visual test indicator which gives a green signal when an adequate charge level exists, and a dark signal when charging is required. BATTERY VISUAL INSPECTION (2) Make sure the ignition switch is in LOCK (OFF) position and all battery fed accessories are OFF. 1. Disconnect the negative cable from battery before disconnecting the positive cable. WARNING: Care should be taken in the event the battery case is cracked or leaking to protect hands from the electrolyte. A suitable pair of rubber gloves (not the household type) should be worn when removing battery by hand. 2. Remove the battery from the vehicle. 3. Inspect battery carrier for damage caused by loss of acid from the battery. If acid damage is present, it is necessary to clean area with a solution of clean warm water and baking soda. Scrub area with a stiff bristle brush. Wipe clean with a cloth moistened with ammonia or baking soda in water. 4. Clean the battery, especially the top with same solutions as described in step 3. 5. Inspect the battery case and cover for cracks. If cracks are present, battery must be replaced. 6. Clean the battery post with a suitable battery post cleaning tool. 7. Clean the inside surfaces of the terminal clamps with a suitable battery terminal cleaning tool. Replace damaged or frayed cables and broken terminal clamps. 8. Install the battery in the vehicle. 9. Connect the positive and negative cables to the battery in the order of mention. 10. Tighten the clamp nut securely. Battery Charging BATTERY CHARGING WARNING: When batteries are being charged, an explosive gas forms beneath the cover of each chef Do not smoke near batteries on charge or which have recently been charged. Do not break live circuits at the terminals of the batteries on charge. A spark will occur where the five circuit is broken. Keep all open flames away from the battery. Battery electrolyte temperature may temporarily be allowed to rise to 55 °C (131 °F). Increase of electrolyte temperature above 55 °C (131 °F) is harmful to the battery, causing deformation of battery cell, decrease in life of battery, etc. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Procedures > Page 3828 Charge Rate Chart CHARGE RATE If the test indicator is dark, the battery should be charged as outlined below. When the dot appears or when maximum charge shown below is reached, charging should be stopped. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Procedures > Page 3829 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3835 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3836 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3837 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3838 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3839 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3840 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3841 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3842 Alternator: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3843 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3844 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3845 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3846 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3847 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3848 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3849 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3850 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3851 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 3856 Alternator: Testing and Inspection ROTOR CHECK 1. Check the continuity between the slip rings of the field coil. If the resistance value is not within the standard value, replace the rotor. Standard value: Approximately 2-5 ohms 2. Check the continuity between the slip ring and the core. If there is continuity, replace the rotor. STATOR CHECK 1. Check the continuity between the coil lead. If there is no continuity, replace the stator. 2. Check the continuity between the coil and the core. If there is continuity, replace the stator. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 3857 RECTIFIER CHECK 1. Check the continuity between the positive rectifier and the stator coil lead connection terminal with a tester. If there is continuity between the terminals, the diode is shorted, so replace the rectifier. 2. Check the continuity between the negative rectifier and the stator coil lead connection terminal with a tester. If there is continuity between the terminals, the diode is grounded, so replace the rectifier. 3. Check the continuity of the three diodes by connecting an ohmmeter to both ends of each diode. If there is continuity between the directions, or if there is no continuity, the diode is damaged, so replace the rectifier. BRUSH CHECK 1. Replace the brush if the brush protrusion length shown in the illustration is below the minimum limit value. Minimum limit: 2 mm (0.08 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 3858 2. The brush can be removed by unsoldering the brush lead wire. 3. When installing a new brush, push the brush in to the brush holder, and solder the lead wire. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation Alternator: Service and Repair Removal and Installation Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 3861 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 3862 Alternator: Service and Repair Disassembly and Assembly Disassembly And Assembly DISASSEMBLY SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 3863 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Removal and Installation > Page 3864 >>A<< REGULATOR ASSEMBLY INSTALLATION After installing the regulator assembly, insert a wire through the hole provided on the rear bracket while pressing down on the brush, and secure the brush. NOTE: By inserting a wire, the brush will be secured in place, and the installation of the rotor will be easier >>B<< ROTOR ASSEMBLY INSTALLATION After installing the rotor, remove the wire used to secure the brush. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Overall View View P Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions Neutral Safety Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Neutral Safety Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 3892 Neutral Safety Switch: Testing and Inspection PARK/NEUTRAL POSITION SWITCH CONTINUITY CHECK PARK/NEUTRAL POSITION SWITCH CONTINUITY CHECK Part 1 of 2 Part 2 of 2 NOTE: For vehicles with sport mode, four positions (P, R, N, D) are used. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 3893 Neutral Safety Switch: Adjustments PARK/NEUTRAL POSITION SWITCH AND CONTROL CABLE ADJUSTMENT 1. Set the selector lever to the "N" position. 2. Loosen the control cable to the manual control lever coupling nut to free the cable and lever. 3. Set the manual control lever to the neutral position. 4. Loosen the park/neutral position switch body mounting bolts and turn the park/neutral position switch body so the hole in the end of the manual control lever and the hole (section A - A in the figure on the left) in the flange of the park/neutral position switch body flange are aligned. NOTE: The park/neutral position switch body can be aligned by inserting a 5-mm diameter steel bar into the end hole of the manual control lever and the flange hole of the park/neutral position switch body. 5. Tighten the park/neutral position switch body mounting bolts to the specified torque. Be careful at this time that the switch body does not move. Tightening torque:...............11 ± 1 Nm (96 ± 8 inch lbs.) 6. Gently push the transaxle control cable in the direction of the arrow, until the cable is taut. Tighten the adjusting nut. Tightening torque:.................12 ± 2 Nm (107 ± 17 inch lbs.) 7. Check that the selector lever is in the "N" position. 8. Check that each position of the manual control lever matches each position of the selector lever and using scan tool. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment Starter Motor: Testing and Inspection Pinion Gap Adjustment 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. 2. Connect a 12-volt battery between the S-terminal and M-terminal. CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 3. Set the switch to ON, and the pinion will move out. 4. Check the pinion-to-stopper clearance (pinion gap) with a feeler gauge. Standard value: 0.5 - 2.0 mm (0.02-0.07 inch) 5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3898 Starter Motor: Testing and Inspection Magnetic Switch Pull-In Test 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal and M-terminal. 3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the magnetic switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3899 Starter Motor: Testing and Inspection Magnetic Switch Hold-In Test 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal and body. 3. Manually pull out the pinion as far as the pinion stopper position. 4. If the pinion remains out, everything is operating properly. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3900 Starter Motor: Testing and Inspection Free Running Test 1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to the starter motor as follows: 2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the positive battery terminal and starter motor terminal. 3. Connect a voltmeter (15-volt scale) across the starter motor. 4. Rotate carbon pile to full-resistance position. 5. Connect the battery cable from the negative battery terminal to the starter motor body. 6. Adjust the rheostat until the battery positive voltage shown by the voltmeter is 11 V. 7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: maximum 90 Amps Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3901 Starter Motor: Testing and Inspection Pinion Gap Adjustment 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. 2. Connect a 12-volt battery between the S-terminal and M-terminal. CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 3. Set the switch to ON, and the pinion will move out. 4. Check the pinion-to-stopper clearance (pinion gap) with a feeler gauge. Standard value: 0.5 - 2.0 mm (0.02-0.07 inch) 5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket. Magnetic Switch Pull-In Test Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3902 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal and M-terminal. 3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the magnetic switch. Magnetic Switch Hold-In Test 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal and body. 3. Manually pull out the pinion as far as the pinion stopper position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3903 4. If the pinion remains out, everything is operating properly. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch. Free Running Test 1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to the starter motor as follows: 2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the positive battery terminal and starter motor terminal. 3. Connect a voltmeter (15-volt scale) across the starter motor. 4. Rotate carbon pile to full-resistance position. 5. Connect the battery cable from the negative battery terminal to the starter motor body. 6. Adjust the rheostat until the battery positive voltage shown by the voltmeter is 11 V. 7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: maximum 90 Amps Magnetic Switch Return Test 1. Disconnect the field coil wire from the M-terminal of the magnetic switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3904 CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the M-terminal and body. WARNING: Be careful not to get your fingers caught when pulling out the pinion. 3. Pull the pinion out and release. If the pinion quickly returns to its original position, everything is operating properly. If it doesn't, replace the magnetic switch. Inspection COMMUTATOR CHECK 1. Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge. Standard value: 0.05mm (0.002 inch) Limit 0.1mm (0.004 inch) 2. Check the outer diameter of the commutator. Standard value: 29.4 mm (1.16 inch) Minimum limit: 28.8mm (1.13 inch) 3. Check the depth of the undercut between segments. Standard value: 0.5 mm (0.02 inch) Minimum limit: 0.2 mm (0.008 inch) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3905 ARMATURE CHECK 1. Check that the armature coil is not grounded. 2. Place the armature in a growler. 3. Hold a thin steel blade parallel and just above the armature while slowly rotating in the growler. A shorted armature will cause a blade to vibrate and be attracted to the core. Replace the shorted armature. 4. Check the insulation between the armature coil cores and the commutator segments. They are normal if there is no continuity. 5. Check for continuity between the segments. The condition is normal if there is continuity. BRUSH HOLDER CHECK Check for the continuity between the brush holder plate and the brush holder. There should be no continuity. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Pinion Gap Adjustment > Page 3906 BRUSH CHECK 1. Brushes that are worn beyond wear limit line, or oil-soaked, should be replaced. 2. When replacing the ground brush, slide the brush from the brush holder by prying the retaining spring back. OVERRUNNING CLUTCH CHECK 1. While holding the clutch housing, rotate the pinion. The drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If the clutch does not function properly, replace the overrunning clutch assembly. 2. Inspect the pinion for wear or burrs. If the pinion is worn or burred, replace the overrunning clutch assembly. If the pinion is damaged, also inspect the ring gear for wear or burrs. FRONT AND REAR BRACKET BUSHING CHECK Inspect the bushing for wear or burrs. If the bushing is worn or burred, replace the front bracket assembly or rear bracket assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Assembly Starter Motor: Service and Repair Disassembly and Assembly Disassembly And Assembly DISASSEMBLY SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Assembly > Page 3909 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Disassembly and Assembly > Page 3910 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions Starter Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3916 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3917 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 Starter Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3927 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3928 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Diagrams > Page 3937 Starter Relay: Service and Repair Starter Relay Check STARTER RELAY CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Auxiliary Power Outlet: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3958 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3959 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3960 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-12-2 Junction Block (Top) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3967 8w-12-3 Junction Block (Bottom) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3968 Circuit Breakers Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction Fuse: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 3973 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 3974 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 3975 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 3976 Fuse: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 3977 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 3978 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 Fuse: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction Fuse: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4004 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4005 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4006 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4007 Fuse: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4008 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4009 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction Fuse Block: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4014 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4015 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4016 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4017 Fuse Block: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4018 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4019 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 Fuse Block: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Fuse Block: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction Fuse Block: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4047 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4048 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4049 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4050 Fuse Block: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4051 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4052 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4056 Centralized Junction/Fusible Link And Fuse Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4057 Centralized Junction/Fusible Link And Fuse Part 2 Fusible Links 1-25 (Relay Box In Engine Compartment) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4058 Fusible Link 26 (Connected Directly To Battery Positive Terminal) , Fusible Link 27 (Connected In Front Of The Fusible Link Box) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4059 Passenger Compartment (In Junction Block) Part 1 Passenger Compartment (In Junction Block) Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4060 Fuses 1 - 24 (In Junction Block) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4061 Fusible Link: Application and ID Centralized Junction/Fusible Link And Fuse Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4062 Centralized Junction/Fusible Link And Fuse Part 2 Fusible Links 1-25 (Relay Box In Engine Compartment) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4063 Fusible Link 26 (Connected Directly To Battery Positive Terminal) , Fusible Link 27 (Connected In Front Of The Fusible Link Box) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4064 Passenger Compartment (In Junction Block) Part 1 Passenger Compartment (In Junction Block) Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4065 Fuses 1 - 24 (In Junction Block) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Locations Grounding Cable Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Locations Grounding Point: Locations Grounding Overall View Views 1 - 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Locations > Page 4072 Views 4 - 14 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Locations > Page 4073 View 15 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions Grounding Point: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Grounding Point: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 Multiple Junction Connector: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4118 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4119 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4120 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Locations Fusible Link, Fuse And IOD Or Storage Connector Location Index, Overall View And Views A - D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction Relay Box: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4130 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4131 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4132 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4133 Relay Box: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4134 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4135 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Box: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4143 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4144 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4145 Relay Box: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4146 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4147 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4148 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4149 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4150 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 Relay Box: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction Relay Box: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4163 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4164 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4165 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4166 Relay Box: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4167 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4168 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction Relay Box: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4173 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4174 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4175 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4176 Relay Box: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4177 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4178 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Box: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Relay Box: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 Relay Box: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction Relay Box: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4206 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4207 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4208 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4209 Relay Box: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4210 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4211 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Locations Fusible Link, Fuse And IOD Or Storage Connector Location Index, Overall View And Views A - D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4221 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4222 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4223 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4224 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4225 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4226 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4227 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4228 Auxiliary Power Outlet: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4229 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4230 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4231 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4232 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4233 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4234 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4235 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4236 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4237 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4238 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4239 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4240 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4241 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-12-2 Junction Block (Top) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4245 8w-12-3 Junction Block (Bottom) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4246 Circuit Breakers Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction Fuse: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 4251 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 4252 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 4253 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 4254 Fuse: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 4255 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Centralized Junction > Page 4256 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4259 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 Fuse: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction Fuse: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4282 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4283 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4284 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4285 Fuse: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4286 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Centralized Junction > Page 4287 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction Fuse Block: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4292 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4293 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4294 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4295 Fuse Block: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4296 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Centralized Junction > Page 4297 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4300 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4301 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4302 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4303 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4304 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4305 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4306 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4307 Fuse Block: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4308 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Fuse Block: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction Fuse Block: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4325 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4326 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4327 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4328 Fuse Block: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4329 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Centralized Junction > Page 4330 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4334 Centralized Junction/Fusible Link And Fuse Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4335 Centralized Junction/Fusible Link And Fuse Part 2 Fusible Links 1-25 (Relay Box In Engine Compartment) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4336 Fusible Link 26 (Connected Directly To Battery Positive Terminal) , Fusible Link 27 (Connected In Front Of The Fusible Link Box) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4337 Passenger Compartment (In Junction Block) Part 1 Passenger Compartment (In Junction Block) Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4338 Fuses 1 - 24 (In Junction Block) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4339 Fusible Link: Application and ID Centralized Junction/Fusible Link And Fuse Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4340 Centralized Junction/Fusible Link And Fuse Part 2 Fusible Links 1-25 (Relay Box In Engine Compartment) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4341 Fusible Link 26 (Connected Directly To Battery Positive Terminal) , Fusible Link 27 (Connected In Front Of The Fusible Link Box) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4342 Passenger Compartment (In Junction Block) Part 1 Passenger Compartment (In Junction Block) Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 4343 Fuses 1 - 24 (In Junction Block) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Locations Grounding Cable Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Locations Grounding Point: Locations Grounding Overall View Views 1 - 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Locations > Page 4350 Views 4 - 14 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Locations > Page 4351 View 15 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions Grounding Point: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4354 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4355 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4356 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Grounding Point: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4372 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 Multiple Junction Connector: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4394 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4395 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4396 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4397 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4398 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4399 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Locations Fusible Link, Fuse And IOD Or Storage Connector Location Index, Overall View And Views A - D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction Relay Box: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4408 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4409 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4410 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4411 Relay Box: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4412 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4413 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Box: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4416 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4417 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4418 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Relay Box: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4432 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4433 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4434 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4436 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4437 Relay Box: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4438 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction Relay Box: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4441 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4442 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4443 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4444 Relay Box: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4445 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4446 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction Relay Box: Locations Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4451 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4452 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4453 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4454 Relay Box: Locations Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4455 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Centralized Junction > Page 4456 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions Relay Box: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4459 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4460 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4461 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4462 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4463 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4464 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4465 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4466 Relay Box: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4467 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4468 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4469 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4470 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4471 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4472 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4473 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4474 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4475 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4476 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4477 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4480 Relay Box: Electrical Diagrams Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Diagram Information and Instructions > Page 4481 Junction Block Part - Front/Rear Views Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction Relay Box: Application and ID Centralized Junction Relay Location Fusible Link and Fuse Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4484 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4485 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4486 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4487 Relay Box: Application and ID Junction Block Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4488 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Centralized Junction > Page 4489 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Locations Fusible Link, Fuse And IOD Or Storage Connector Location Index, Overall View And Views A - D Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Alignment: Specifications Front FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT Required Special Tool: - MB991004: Wheel Alignment Gauge Attachment. Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition before measuring wheel alignment. TOE-IN Standard value: 0 ± 3 mm (0 ± 0.12 inch) 1. Adjust the toe-in by undoing the clip and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. 2. Use a turning radius gauge to check that the steering angle is at the standard value. STEERING ANGLE Standard value: CAMBER AND CASTER Standard value: Camber 0 ° 00' ± 30'(Left/right deviation within 30') Caster 3 ° 00' ± 30'(Left/right deviation within 30') NOTE: Caster is preset at the factory and cannot be adjusted. CAUTION: Never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened. NOTE: For vehicles with aluminum type wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool MB991004. Tighten special tool MB991004 to the same torque 226 ± 29 Nm (167 ± 21 ft. lbs.) as the driveshaft nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front > Page 4499 If the camber is outside of the standard value, perform the following adjustment procedures. 1. Estimate how much additional camber adjustment is required. Using the table below, select the camber adjusting bolt, and then replace the knuckle and strut assembly connection bolts (upper bolt, lower bolt) with the selected bolts. NOTE: Set bolt is the bolt installed at factory. "10 " embossed on bolt head is head mark. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front > Page 4500 2. Tighten the nuts temporarily, and then pull or push the front axle to adjust the camber. NOTE: Pulling the upper side of the front axle to the outside of the vehicle will increase the camber. Pushing it to the inside of the vehicle will decrease the camber. 3. Tighten the nuts to 300 ± 24 Nm (221 ± 18 ft. lbs.). 4. Recheck the camber. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front > Page 4501 Alignment: Specifications Rear REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure wheel alignment with an alignment equipment on level ground. The rear suspension and wheels should be serviced to the normal condition prior to wheel alignment. TOE-IN Standard value: 3 ± 3 mm (0.12 ± 0.12 inch) Loosen nut, then turn the toe control arm mounting bolt to adjust toe. NOTE: LH: Clockwise viewed from the rear -> Toe-out - RH: Clockwise viewed from the rear -> Toe-in - Toe adjustment can be made at graduations of approximately 2.5 mm (0.10 inch). CAMBER Standard value: -1°20'+ 30' (Difference between right and left within 30') NOTE: Camber is preset at the factory and cannot be adjusted. NOTE: If camber is not within the standard value, check and replace bent or damaged parts. Dimension for positioning upper arm bracket mm (in) ............................................................................................................... 37.2 +/-2 (1.46 +/- 0.08) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Suspension Alignment: Service and Repair Front Suspension FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT Required Special Tool: - MB991004: Wheel Alignment Gauge Attachment. Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition before measuring wheel alignment. TOE-IN Standard value: 0 ± 3 mm (0 ± 0.12 inch) 1. Adjust the toe-in by undoing the clip and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. 2. Use a turning radius gauge to check that the steering angle is at the standard value. STEERING ANGLE Standard value: CAMBER AND CASTER Standard value: Camber 0 ° 00' ± 30'(Left/right deviation within 30') Caster 3 ° 00' ± 30'(Left/right deviation within 30') NOTE: Caster is preset at the factory and cannot be adjusted. CAUTION: Never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened. NOTE: For vehicles with aluminum type wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool MB991004. Tighten special tool MB991004 to the same torque 226 ± 29 Nm (167 ± 21 ft. lbs.) as the driveshaft nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Suspension > Page 4504 If the camber is outside of the standard value, perform the following adjustment procedures. 1. Estimate how much additional camber adjustment is required. Using the table below, select the camber adjusting bolt, and then replace the knuckle and strut assembly connection bolts (upper bolt, lower bolt) with the selected bolts. NOTE: Set bolt is the bolt installed at factory. "10 " embossed on bolt head is head mark. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Suspension > Page 4505 2. Tighten the nuts temporarily, and then pull or push the front axle to adjust the camber. NOTE: Pulling the upper side of the front axle to the outside of the vehicle will increase the camber. Pushing it to the inside of the vehicle will decrease the camber. 3. Tighten the nuts to 300 ± 24 Nm (221 ± 18 ft. lbs.). 4. Recheck the camber. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Suspension > Page 4506 Alignment: Service and Repair Rear Suspension REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT Measure wheel alignment with an alignment equipment on level ground. The rear suspension and wheels should be serviced to the normal condition prior to wheel alignment. TOE-IN Standard value: 3 ± 3 mm (0.12 ± 0.12 inch) Loosen nut, then turn the toe control arm mounting bolt to adjust toe. NOTE: LH: Clockwise viewed from the rear -> Toe-out - RH: Clockwise viewed from the rear -> Toe-in - Toe adjustment can be made at graduations of approximately 2.5 mm (0.10 inch). CAMBER Standard value: -1°20'+ 30' (Difference between right and left within 30') NOTE: Camber is preset at the factory and cannot be adjusted. NOTE: If camber is not within the standard value, check and replace bent or damaged parts. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair REMOVAL AND INSTALLATION INSPECTION Check the knuckle surface for galling and cracks. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair POWER STEERING SYSTEM BLEEDING Perform air bleeding procedure as necessary after replacing the steering gear box or the steering fluid lines. 1. Raise and support the front wheels. 2. Disconnect the high-tension cable. Turn the steering wheel all the way to the left and right five or six times while using the starter motor to crank the engine intermittently several times (for 15 to 20 seconds). CAUTION: Be careful not to place the high-tension cable near the fuel rail. - Perform air bleeding only while cranking the engine. If air bleeding is performed while the engine is running, air could enter the fluid. During air bleeding, refill the steering fluid supply so that the level never falls below the lower mark on the dipstick. 3. Connect the high-tension cable. Start the engine (idling). 4. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir. 5. Confirm that the fluid is not milky, and that the level is between the high and low dipstick marks. 6. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right. 7. Confirm that the change in the fluid level is no more than 5 mm (0.2 inch) when the engine is stopped and when it is running. CAUTION: If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control valve, and this condition could cause reduce the life of the power steering components. 8. If the change of the fluid level is 5 mm (0.2 inch) or more, the air has not been completely bled from the system. Air bleeding procedure must be repeated. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4524 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4525 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4526 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4527 Power Steering Fluid: Technical Service Bulletins A/T, Power Steering - ATF+4 Fluid Usage NUMBER: 21-003-02 GROUP: Transmission DATE: Jul. 29, 2002 SUBJECT: ATF+4 Usage OVERVIEW: This bulletin provides information about ATF+4 usage in ST22 models. MODELS: 2001 - 2003 (ST) Sebring/Stratus Coupe DISCUSSION: ATF+4 (type 9602) is approved for use in Sebring/Stratus Coupe power steering and automatic transaxles. The fluid is fully compatible in power steering systems and no additional maintenance information is required. When using ATF+4 in automatic transaxles, the following information is required for proper service and maintenance. SCHEDULED MAINTENANCE When using ATF+4 as a complete fill in Sebring/Stratus Coupe models, the maintenance for schedule A is changed to a 60,000 mile fluid replacement interval. Schedule B remains the same as listed in the owners manual. The owner should be notified about this schedule change when ATF+4 is used as a complete fill. NOTE: USING ATF+4 FOR TOP OFF WILL NOT CHANGE THE ORIGINAL CHARACTERISTICS OF THE FACTORY FILL OR ORIGINAL MAINTENANCE SCHEDULE. GENERAL SERVICE FILL ATF+4 is fully compatible for top off or for any transaxle service procedures that would require fluid fill or fluid replacement. Special considerations are required if a new torque converter is installed. TORQUE CONVERTER REPLACEMENT If a new torque converter is installed, ATF+4 can be used however, green torque converter shudder MAY be experienced. If green torque converter shudder is experienced, it will be eliminated over time as the torque converter clutches wear or burnish in. If shudder occurs, the vehicle can be driven (in torque converter partial lockup) until the condition is eliminated. If customer concerns arise due to green torque converter shudder use the following procedure. NOTE: TO ELIMINATE ANY CONCERNS OF GREEN TORQUE CONVERTER SHUDDER, THE TRANSAXLE CAN BE FILLED WITH DIAMOND SPIII FLUID PN 05073942AA DURING THE INITIAL FILL. 1. Drain and refill the transaxle with a minimum of 80% Diamond SPIII Transmission Fluid pn 05073942AA. 2. Warm the transaxle (by driving) to a minimum of 40 degrees C (104 degrees F). 3. Drive the vehicle for 50 kilometers (30 miles) in a speed range as shown to keep the transaxle torque converter in partial lock up. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4528 PARTS REQUIRED POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid ........................................................................................................................... ........................................................ 0.9dm3 (0.95qt) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 4531 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Type ....................................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4532 Power Steering Fluid: Testing and Inspection FLUID LEVEL CHECK 1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). 2. With the engine running, turn the wheel all the way to the left and right several times. 3. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm (0.2 inch) or more, air bleeding should be done. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 4533 Power Steering Fluid: Service and Repair FLUID REPLACEMENT 1. Raise and support the front wheels. 2. Disconnect the return hose connection. 3. Connect a vinyl hose to the return hose, and drain the fluid into a container. CAUTION: Be careful not to position the high-tension cable near the fuel rail. 4. Disconnect the high-tension cable. 5. While operating the starting motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid. 6. Connect the return hoses securely, and then secure with the clip. 7. Fill the oil reservoir with Automatic transmission fluid DEXRON 1103 to the lower position of the filler, and then bleed the air. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Oil Pump eye bolt 42 +/- 5 ft. lb. Oil reservoir, pressure hose, pressure tube, return tube, cooler tube bolt 100 +/- 22 in. lb. Pressure tube flare nut (Gear Box side) 11 +/- 2 ft. lb. Pressure tube flare nut (Pressure Hose side) 26 +/- 3 ft. lb. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4537 Power Steering Line/Hose: Service and Repair POWER STEERING HOSES <2.4L ENGINE> REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4538 <3.0L ENGINE> INSTALLATION SERVICE POINTS >>A<< PRESSURE TUBE ASSEMBLY INSTALLATION Align the marks on the pressure tube assembly and steering gear box, and install the pressure tube assembly. >>B<< RETURN HOSE ASSEMBLY INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4539 1. Align the marks on the return hose assembly and steering gear box, and install the return hose assembly. 2. Install the return hose assembly so that the marking is positioned as shown in the illustration. >>C<< PRESSURE HOSE INSTALLATION 1. Install the pressure hose at the gear box side so that the marking is positioned as shown in the illustration. 2. Install the pressure hose at the power steering oil pump side as shown in the illustration. >>D<< RETURN HOSE INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 4540 Install the return hose so that the markings are positioned as shown in the illustration. >>E<< SUCTION HOSE INSTALLATION Install the suction hose so that the markings are positioned as shown in the illustration. >>F<< RETURN HOSE INSTALLATION Install the-return hose so that the markings are positioned as shown in the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4545 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4546 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4547 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Oil Pump bracket bolt M8 21 +/- 3 ft. lb. M10 36 +/- 7 ft. lb. Oil Pump eye bolt 42 +/- 5 ft. lb. Pressure hose bolt 100 +/- 22 in. lb. Type Vane Type Displacement 0.59 cuin/rev Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 4550 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Oil pump relief pressure 1209 - 1280 psi pressure under no-load conditions 116 - 145 psi Steering gear retention hydraulic pressure 1209 - 1280 psi Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4551 Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4552 Power Steering Pump: Testing and Inspection OIL PUMP PRESSURE TEST Required Special Tools: MB990662: Pressure Gauge - MB991548: Power Steering Oil Pressure Gauge Adapter (Pump Side) - MB991549: Power Steering Oil Pressure Gauge Adapter (Hose Side) 1. Disconnect the pressure hose from the oil pump, and then connect special tools MB991548, MB990662 and MB991549. 2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 60°C (122 - 140°F). 3. Start the engine and idle it at 1,000 + 100 r/min. CAUTION: The pressure gauge shut-off valve must not remain closed for more than 10 seconds. 4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Open it again immediately after checking the pressure. Standard value: 8.3 - 9.5 MPa (1,209 1,280 psi) 5. If it is not within the standard value, replace the oil pump. 6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge. Standard value: 0.8 - 1.0 MPa (116 - 145 psi) 7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear box, so check these parts and repair as necessary. 8. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value. Standard value: 8.3 - 9.5 MPa (1,209 - 1,280 psi) 9. If not the standard value, overhaul the steering gear box. Remeasure fluid pressure. 10. Remove special tools MB991548, MB990662 and MB991549, and then tighten the pressure hose to the specified torque. Tightening torque: 57 ± 7 Nm (42 ± 5 ft. lbs.) 11. Bleed the system. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4553 Power Steering Pump: Service and Repair POWER STEERING OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION INSPECTION Check the drive belt for cracks. Check the drive shaft assembly for uneven rotation. POWER STEERING HOSES REMOVAL AND INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4554 <2.4L ENGINE> Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4555 <3.0L ENGINE> INSTALLATION SERVICE POINTS >>A<< PRESSURE TUBE ASSEMBLY INSTALLATION Align the marks on the pressure tube assembly and steering gear box, and install the pressure tube assembly. >>B<< RETURN HOSE ASSEMBLY INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4556 1. Align the marks on the return hose assembly and steering gear box, and install the return hose assembly. 2. Install the return hose assembly so that the marking is positioned as shown in the illustration. >>C<< PRESSURE HOSE INSTALLATION 1. Install the pressure hose at the gear box side so that the marking is positioned as shown in the illustration. 2. Install the pressure hose at the power steering oil pump side as shown in the illustration. >>D<< RETURN HOSE INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4557 Install the return hose so that the markings are positioned as shown in the illustration. >>E<< SUCTION HOSE INSTALLATION Install the suction hose so that the markings are positioned as shown in the illustration. >>F<< RETURN HOSE INSTALLATION Install the return hose so that the markings are positioned as shown in the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations Overall View View B Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Key Reminder Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4583 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4584 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4585 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4586 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4587 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Key Reminder Switch: Electrical Diagrams Forgotten Key Prevention Function Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Forgotten Key Prevention Function Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Forgotten Key Prevention Function Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Forgotten Key Prevention Function Part 4 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Page 4595 Key Reminder Switch: Testing and Inspection Disconnect key reminder switch connector without removing the ignition switch and steering lock cylinder. Key reminder switch check Check for continuity between terminal 4 and terminal 6. Ignition key ring antenna check Check for continuity between terminal 3 and terminal 7. Standard value: Should be less than 2 ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications Steering Gear: Mechanical Specifications Power Steering Gear box Cylinder Clamp assembly nut, gear box assembly bolt 51 +/- 7 ft. lb. End plug 44 +/- 7 ft. lb. Feed Tube Flare nut 113 +/- 26 in. lb. Pinion and valve assembly jam nut 18 +/- 3 ft. lb. Rack support cover 109 +/- 21 in. lb. Rack support cover jam nut 44 +/- 7 ft. lb. Return hose flare nut, pressure tube flare nut 11 +/- 2 ft. lb. Steering Shaft and gear box connecting bolt 13 +/- 2 ft. lb. Stay bolt 55 +/- 3 ft. lb. Power Steering Gear box Type Rack and Pinion Gear ratio 45.74 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Mechanical Specifications > Page 4600 Steering Gear: Pressure, Vacuum and Temperature Specifications Steering gear retention hydraulic pressure 1,209 - 1,280 psi Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4601 Steering Gear: Service and Repair POWER STEERING GEAR BOX ASSEMBLY REMOVAL AND INSTALLATION WARNING: Before removing the steering gear box center the front wheels. Failure to do so may damage the SRS clock spring and render the SRS system inoperative risking serious injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4602 <3.0L ENGINE> REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4603 Align the marks on the pressure tube assembly and steering gear box, and install the pressure tube assembly. >>B<< RETURN HOSE ASSEMBLY INSTALLATION Align the marks on the return hose assembly and steering gear box, and install the return hose assembly. INSPECTION GEAR BOX TOTAL PINION TORQUE CHECK CAUTION: When holding the steering gear box assembly in a vice, secure its mounting positions. If it Is secured in any other places, the gear housing may become deformed or damaged. Using special tool MB990228 or MB991006, rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque. Standard value: 0.8 -1.9 Nm (6.9-16.5 inch lbs.) [Change in torque: 0.7 Nm (6.1 inch lbs.) or less] NOTE: When measuring, remove the bellows from the rack housing. Measure the pinion torque through the whole stroke of the rack. If the measured value is not within the standard range, first adjust the rack support cover, and then check the total pinion torque again. If the total pinion torque cannot be adjusted to within the standard range by adjusting the rack support cover, check the rack support cover, rack support spring, rack support and replace any parts if necessary. TIE ROD SWING RESISTANCE CHECK 1. Give 10 hard swings to the tie rod. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4604 2. Measure the tie rod swing resistance with a spring balance. Standard value: 4.0 - 18.6 N (17.8 - 82.7 lbs.) [1.0 - 4.9 Nm (8.7 - 43.4 inch lbs.)] 3. If the measured value exceeds the standard value, replace tie rod. 4. If the measured value is below the standard value, the tie rod can be re-used if it swings smoothly without excessive play. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Power steering wheel and shaft Clock spring and column switch assermbly bolt 18 +/- 4 ft. lb. Steering Shaft and gear box connecting bolt 13 +/- 1 ft. lb. Steering column assembly bolt 100 +/- 22 in. lb. Steering Cover bolt 44 +/- 8 in. lb. Steering Wheel nut 31 +/- 5 ft. lb. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 4608 Steering Shaft: Service and Repair STEERING WHEEL AND SHAFT ASSEMBLY REMOVAL AND INSTALLATION WARNING: Before removing the air bag module, refer to Service Precautions end Air Bag Module and Clock Spring. - When removing and installing the steering wheels do not let it bump against the air bag module. REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 4609 CAUTION: Do not hammer on the steering wheel to remove it; doing so will damage the collapsible mechanism. Use special tool MB990803 to remove the steering wheel. INSTALLATION SERVICE POINT >>A<< STEERING COVER ASSEMBLY INSTALLATION 1. Mount steering cover assembly in the steering gear box securely at the groove, so that the clearance A (shown in the illustration at left) will be at the standard value. Standard value (A): 0 - 0.5 mm (0 - 0.02 inch) 2. Before bolting, apply 3MTM Part number 8663 or equivalent to the mounting bolt holes of toeboard. DISASSEMBLY AND ASSEMBLY Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 4610 DISASSEMBLY SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Power steering wheel and shaft Clock spring and column switch assermbly bolt 18 +/- 4 ft. lb. Steering Shaft and gear box connecting bolt 13 +/- 1 ft. lb. Steering column assembly bolt 100 +/- in. lb. Steering Cover bolt 44 +/- 8 in. lb. Steering Wheel nut 31 +/- 5 ft. lb. Steering Wheel free play With engine running Limit 1.2 in. With engine stopped 0.4 in. or less Steering Angle Inside wheel 36 degrees 12' +/- 2 degrees 00' Outside Wheel (reference) 30 degrees 24' Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Steering Wheel Free Play Check Steering Wheel: Testing and Inspection Steering Wheel Free Play Check STEERING WHEEL FREE PLAY CHECK 1. With the engine running (hydraulic operation), set the front wheels straight ahead. 2. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm (1.2 inch) 3. When the play exceeds the limit, check for the play on the steering shaft and steering linkage connection. Correct or replace. 4. If the free play still exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Load 5 N (1.1 pound) towards the steering wheel circumference and check the play. Standard value (steering wheel play with the engine stopped): 10 mm (0.4 inch) or less 5. If the play exceeds the standard value, check the steering gear box and check total pinion torque. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Steering Wheel Free Play Check > Page 4616 Steering Wheel: Testing and Inspection Steering Wheel Return to Center Check STEERING WHEEL RETURN TO CENTER CHECK Conduct a road test: 1. Make both gradual and sudden turns and check the steering 2. At a speed of approximately 35 km/h (22 mph), turn the steering wheel 90 degrees, hold a few seconds, then release. If the steering wheel then returns 70 degrees or more, the return can be judged satisfactory. NOTE: There will be a momentary feeling or "heaviness" when the wheel is turned quickly, but this is not abnormal. (Oil pump discharge amount is especially apt to be insufficient during idling.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Page 4617 Steering Wheel: Service and Repair STEERING WHEEL AND SHAFT ASSEMBLY REMOVAL AND INSTALLATION WARNING: Before removing the air bag module, refer to Service Precautions end Air Bag Module and Clock Spring. - When removing and installing the steering wheels do not let it bump against the air bag module. REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Page 4618 CAUTION: Do not hammer on the steering wheel to remove it; doing so will damage the collapsible mechanism. Use special tool MB990803 to remove the steering wheel. INSTALLATION SERVICE POINT >>A<< STEERING COVER ASSEMBLY INSTALLATION 1. Mount steering cover assembly in the steering gear box securely at the groove, so that the clearance A (shown in the illustration at left) will be at the standard value. Standard value (A): 0 - 0.5 mm (0 - 0.02 inch) 2. Before bolting, apply 3MTM Part number 8663 or equivalent to the mounting bolt holes of toeboard. DISASSEMBLY AND ASSEMBLY Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Testing and Inspection > Page 4619 DISASSEMBLY SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod End Nut 38 +/- 2 ft. lb. Tie Rod End to knuckle fixing nut 21 +/- 4 ft. lb. Tie Rod End ball joint breakaway torque 4.4 - 22.1 in. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway Tie Rod End: Testing and Inspection Tie Rod End Ball Joint Breakaway TIE ROD END BALL JOINT BREAKAWAY TORQUE CHECK Required Special Tools: MB990326: Preload Socket - MB991113 or MB990635: Steering Linkage Puller CAUTION: Use special tool MB991113 or MB990635 to loosen the nut from the ball joint instead of removing it. - Hang special tool MB991113 or MB990635 with ropes to prevent it from falling. 1. Use special tool MB991113 or MB990635 to disconnect the ball joint. 2. Move the ball joint stud several times and install the nut on the stud. Measure the ball joint breakaway torque with special tool MB990326. Standard value: 0.5 - 2.5 Nm (4.4 - 22.1 inch lbs.) 3. If the breakaway torque exceeds the standard value, replace the tie rod end. 4. If the breakaway torque is under the standard value, check the ball joint for end play or ratcheting. If no end play or ratcheting, the ball joint can be re-used. 5. Tighten the nut to the specified torque and install a new cotter pin. Tightening torque: 29 ± 4 Nm (21 ± 4 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4626 Tie Rod End: Testing and Inspection Tie Rod End Ball Joint Dust Cover Check TIE ROD END BALL JOINT DUST COVER CHECK 1. Check the dust cover for cracks or damage by pushing it with your finger. 2. If the dust cover is cracked or damaged, replace the tie rod end. NOTE: Cracks or damage of the dust cover may damage the ball joint. If it is damaged during service work, replace the dust cover. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4627 DISASSEMBLY AND ASSEMBLY LUBRICATION AND SEALING POINTS DISASSEMBLY SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4628 Unstake the tab washer which secures the tie rod and rack with a chisel. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4629 Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously. <> CIRCLIP REMOVAL CAUTION: If the rack stopper is first turned counterclockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn. 1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing. 2. Turn the rack stopper counterclockwise to remove the circlip. <> RACK REMOVAL Pull out the rack slowly. At this time also take out the rack stopper and the rack bushing simultaneously. <> OIL SEAL REMOVAL CAUTION: Do not damage oil seal press fitting surface. Partially bend oil seal and remove from rack bushing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4630 Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing. <> NEEDLE ROLLER BEARING REMOVAL CAUTION: Do not open special tool MB991120 excessively to prevent damaging housing interior. Use special tool MB991120 to remove the needle roller bearing from the rack housing. <> OIL SEAL REMOVAL CAUTION: Be careful not to damage the inner surface of the rack cylinder of the gear housing. Use a piece of pipe or similar tool to remove the oil seal from the gear housing. ASSEMBLY SERVICE POINT >>A<< OIL SEAL INSTALLATION 1. Apply a coating of the DIAMOND ATF to the both sides of the oil seal. 2. Using special tools MB991199 and MB991197, press the oil seal into the rack housing. >>B<< NEEDLE ROLLER BEARING/BALL BEARING INSTALLATION CAUTION: Press-fit straight. Valve housing is aluminum, and may become deformed if press-fit on an angle. 1. Apply DIAMOND ATF to housing, bearing and oil seal press fitting surface. 2. Press fit needle roller bearing with special tools MB990938 and MB991202. >>C<< 0IL SEAL/D-RING INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4631 1. Apply a coating of the DIAMOND ATF to the outside of the oil seal and O-ring. 2. Use special tool MB990927 to press fit oil seal until it touches rack bush end. >>D<< RACK INSTALLATION CAUTION: Do not close the vent hole in the rack with grease. 1. Apply a coating of MOPAR Multi-mileage Lubrication Part No. 2525035 or equivalent to the rack teeth face. 2. Cover rack serrations with special tool MB991213. 3. Apply DIAMOND ATF to special tool MB991213. 4. Align center of oil seal with rack to prevent retainer spring from slipping. Slowly insert rack from power cylinder side. >>E<< RACK BUSHING INSTALLATION CAUTION: Do not allow oil seal retainer spring to slip out. Wrap the rack end with vinyl tape, apply coating of the DIAMOND ATF, and then install the rack bushing and rack stopper. >>F<< CIRCLIP INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4632 CAUTION: Insert circlip to rack stopper hole whilst turning rack stopper clockwise. Insert circlip to rack stopper hole through cylinder hole. Turn rack stopper clockwise and insert circlip firmly. >>G<< 0IL SEAL/BALL BEARING INSTALLATION Apply a coating of the DIAMOND ATF to the outside of the oil seal. Using special tools MB990938 and MB991203, press the oil seal into the valve housing. >>H<< SEAL RING INSTALLATION Because the seal rings expand after installation, tighten after installing by using special tool MB991317 to compress the rings, or press down by hand. >>I<< 0IL SEAL INSTALLATION CAUTION: To eliminate a seal malfunction at the valve housing alignment surface, the upper surface of the oil seal should project outward approximately 1 mm (0.04 inch) from the housing edge surface. Using special tool MB991152, press the oil seal into the valve housing. >>J<< END PLUG INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4633 1. Apply the 3MTM AAD Part number 8663 or equivalent to the threaded part of the end plug. 2. Secure the threaded portion of the end-plug at two places by using a punch. >>K<< RACK SUPPORT COVER/JAM NUT INSTALLATION 1. Position rack at its center. 2. Apply the 3MTM AAD Part number 8663 or equivalent to the threaded part of the ruck support cover. 3. Use special tool MB991204 to tighten rack support cover to 13 ± 2 Nm (109 ± 21 inch lbs.). 4. Turn the rack support cover by 10 degree counterclockwise. 5. Use special tool MB991204 to hold the rack support cover, and then tighten the jam nut to 59 ± 10 Nm (44 ± 7 ft. lbs.). >>L<< TOTAL PINION TORQUE ADJUSTMENT CAUTION: When adjusting, set at the highest value of the standard value range. - Be sure there is no ratcheting or catching when operating the rack towards the shaft. - Measure the total pinion torque through the whole stroke of the rack. NOTE: If the total pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary. 1. Using special tool MB990228 or MB991006, rotate the pinion shaft at the rate of one rotation in four to six seconds to check the total pinion torque and the change in torque. Standard value: Total pinion torque: 0.8 - 1.9 mm (6.9 - 16.5 inch lbs.) Change in torque: 0.7 Nm (6.1 inch lbs.) or less 2. If the total pinion torque or the change in torque is outside the standard value, return the rack support cover within 0 degree angle to 30 degree angle, and adjust again. >>M<< TAB WASHER/TIE ROD INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4634 After installing tie rod to rack, fold tab washer end (two locations) to tie rod notch. >>N<< BELLOWS BAND INSTALLATION 1. Turn the adjusting bolt of special tool MB991561 to adjust the opening dimension (W) to the standard value. NOTE: The dimension (W) is adjusted by approximately 0. 7 mm per one turn. NOTE: Do not turn the adjusting bolt more than one turn. Standard value (W): 1.9 mm (0.07 inch) : Screw in the adjusting bolt. : Loosen the adjusting bolt. CAUTION: Hold the rack housing, and use special tool MB991561 to crimp the bellows band securely. - Crimp the bellows band until special tool MB9g1561 touches the stopper. 2. Use special tool MB991561 to crimp the bellows band. 3. Check that crimped width (A) is within the standard value. Standard value (A): 1.4 - 1.8 mm (0.06 - 0.07 inch) : Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2). W = 5.5 mm (0.22 inch) - A [Example: if (A) is 1.9 mm (0.07 inch), (W) is 3.6 mm (0.14 inch).] : Remove the bellows band, readjust the dimension (W) of step (1) to the value Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Tie Rod End Ball Joint Breakaway > Page 4635 calculated by the following equation, and use a new bellows band to repeat steps (2) to (3). W = 5.5 mm (0.22 inch) - A [Example: if (A) is 1.3 mm (0.05 inch), (W) is 4.2 mm (0.17 inch).] >>O<< TIE ROD END/TIE ROD END JAM NUT INSTALLATION Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the jam nut. TIE ROD END BALL JOINT DUST COVER REPLACEMENT If the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Apply MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent to the lip and inside of the dust cover. 2. Drive in the dust cover with special tool MB990776 until it is fully seated. 3. Check the dust cover for cracks or damage by pushing it with your finger. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint Wear Limit Specifications Ball Joint: Specifications Ball Joint Wear Limit Specifications Ball Joint Wear Limit ............................................................................................................................ ...................................................................... 0.059" Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint Wear Limit Specifications > Page 4641 Ball Joint: Specifications Lower arm ball joint breakaway Torque 22 - 54 in lbs. If the measured value exceeds the standard value replace the arm. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 4642 Ball Joint: Testing and Inspection BALL JOINT DUST COVER INSPECTION 1. Check dust covers for cracks or damage by pushing it with your finger. 2. If a dust cover is cracked or damaged, replace the toe control arm assembly or stabilizer link. NOTE: Cracks or damage to the dust cover may cause damage to the ball joint. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Ball Joint: Service and Repair Front Suspension Ball Joint Dust Cover Check BALL JOINT DUST COVER CHECK 1. Press the dust cover with your finger to check that there are no cracks or damage in the dust cover. 2. If the dust cover is cracked or damaged, replace the lower arm assembly or stabilizer link. NOTE: If the dust cover is cracked or damaged, it is possible that there may also be damage to the balljoint. Ball Joint Dust Cover Replacement BALL JOINT DUST COVER REPLACEMENT If the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover. 2. Apply specified grease to the lip and inside of the dust cover. Specified grease: Mopar Multi-mileage Lubricant Part No. 2525035 or equivalent 3. Using special tool MB990799, drive in the dust cover until it is fully seated. 4. Using special tool MB991007, drive in the dust cover plate until it contacts the projection of the ball joint. 5. Check the dust cover for cracks or damage by pushing it with your finger. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension > Page 4645 Ball Joint: Service and Repair Rear Suspension TOE CONTROL ARM BALL JOINT DUST COVER REPLACEMENT If the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover. 2. Apply specified grease to inside and lip of the dust cover. Specified Grease: MOPAR Multi-mileage Lubricant Part No.2525035 or equivalent 3. Using special tool MB990800 press the dust cover until it contacts the snap ring. 4. Check the dust cover for cracks or damage by pushing it with your finger. For further information on Toe Control Arm see Control Arm, Lower, Rear. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair LOWER ARM REAR BUSHING REPLACEMENT 1. Position the lower arm bushing so that its arrow mark point the shown direction. 2. Use the special tool MB991446 to press in the bushing to the shown dimension. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications Front Cross-Member: Specifications Crossmember and stay connecting bolt <2.4L Engine> ............................................................................................................... 74 ± 4 Nm (55 ± 3 ft. lbs.) Crossmember mounting bolt .................................................................................................................................................... 108 ± 10 Nm (80 ± 7 ft. lbs.) Crossmember mounting nut ........................................................................................................................................................ 88 ± 10 Nm (65 ± 7 ft. lbs.) Lower arm and crossmember connecting nut ........................................................................................................................... 108 ± 10 Nm (80 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications > Page 4654 Front Cross-Member: Diagrams CROSSMEMBER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications > Page 4655 Front Cross-Member: Service and Repair CROSSMEMBER REMOVAL AND INSTALLATION CAUTION: ^ * Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. ^ For vehicles with SRS, before removal of steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render the SRS system inoperative, risking serious injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications > Page 4656 Required Special Tools: ^ MB990828: Bushing Remover and Installer ^ MB991045: Bushing Remover and Installer CROSSMEMBER BUSHING REPLACEMENT Crossmember Bushings A and B 1. Apply soapy water to the contact surface of the bushing when press-fitted the bushing. 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard values <2.4L ENGINE> ^ Bushing A: 9.0 ± 1.0 mm (0.35 ± 0.04 in.) ^ Bushing B: 4.0 ± 1.0 mm (0.16 ± 0.04 in.) <3.0L ENGINE> ^ Bushing A, B: 9.0 ± 1.0 mm (0.35 ± 0.04 in.) Crossmember Bushing C 1. Use special tool l\4B990828 to drive out and press-fit the Crossmember bushing C. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications > Page 4657 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard value (A): 4.0 ± 0.5 mm (0.16 ± 0.02 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Service and Repair Front Cross-Member Bushing: Service and Repair CROSSMEMBER BUSHING REPLACEMENT Crossmember Bushings A and B 1. Apply soapy water to the contact surface of the bushing when press-fitted the bushing. 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard values ^ Bushing A: 9.0 ± 1.0 mm (0.36 ± 0.04 in.) ^ Bushing B: 4.0 ± 1.0 mm (0.16 ± 0.04 in.) Crossmember Bushing C 1. Use special tool MB990828 to drive out and press-fit the crossmember bushing C. 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard value (A): 4.0 ± 0.5 mm (0.16 ± 0.02 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair REMOVAL AND INSTALLATION INSPECTION Check the knuckle surface for galling and cracks. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair REMOVAL AND INSTALLATION REMOVAL SERVICE POINT << A >> TOE CONTROL ARM DISCONNECTION CAUTION: Use special tool MB991113 or MB990635 to loosen the nut from the ball joint instead of removing it. Hang special tool MB99111. or MB990635 with ropes to prevent it from falling. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front Stabilizer Link: Specifications Stabilizer link nut 33 +/- 7 ft-lb Stabilizer link ball joint breakaway torque 30 - 80 in. lb. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Front > Page 4672 Stabilizer Link: Specifications Stabilizer Link Nut 29 +/- 4 ft. lbs. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Rear Suspension Wire Diameter 0.51 inch Average Diameter 2.1 +/- 0.06 - 3.7 +/-0.06 inch Free Length 10.9 inch Front Suspension Wire Diameter 2.4L - M/T 0.55 in. 2.4L - A/T 0.56 in. 3.0L (D62AHRPEL4C, D62AHRPEL4D, D62AHRPEL5C) 0.57 in. 3.0L ( Except D62AHRPEL4C, D62AHRPEL4D, D62AHRPEL5C) 0.57 in. Average Diameter 2.4L - M/T 0.67 in. 2.4L - A/T 0.67 in. 3.0L (D62AHRPEL4C, D62AHRPEL4D, D62AHRPEL5C) 0.67 in. 3.0L ( Except D62AHRPEL4C, D62AHRPEL4D, D62AHRPEL5C) 0.67 in. Free Length 2.4L - M/T 14.1 in. 2.4L - A/T 14.4 in. 3.0L (D62AHRPEL4C, D62AHRPEL4D, D62AHRPEL5C) 15.1 in. 3.0L ( Except D62AHRPEL4C, D62AHRPEL4D, D62AHRPEL5C) 14.8 in. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Shock Absorber Assembly To Body Nut 32 +/- 4 ft. lbs. Shock Absorber Assembly To Knuckle Bolt 73 +/- 7 ft. lbs. Shock Absorber Jam Nut 17 +/- 1 ft. lbs. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 4680 Suspension Strut / Shock Absorber: Specifications Strut assembly jam nut 47 +/- 4 ft-lb Strut assembly to body connection nut 33 +/- 3 ft-lb Strut assembly to knuckle connection nut 221 +/- 18 ft-lb Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension Strut / Shock Absorber: Service and Repair Rear SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION INSTALLATION SERVICE POINT >>A<< SHOCK ABSORBER ASSEMBLY INSTALLATION Install the shock absorber so that the larger diameter side of the lower bushing inner pipe faces toward the outside of the vehicle. INSPECTION - Check the rubber parts for cracks and wear. - Check the shock absorber for malfunctions, oil leakage, or abnormal noise. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 4683 DISASSEMBLY AND ASSEMBLY NOTE: Vehicles with aluminum wheel Required Special Tools: MB991237: Spring Compressor Body - MB991239: Arm Set DISASSEMBLY SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 4684 MB991239 to slip. This is dangerous. 2. While holding the piston rod, remove the jam nut. ASSEMBLY SERVICE POINTS >>A<< COIL SPRING INSTALLATION CAUTION: Do not use an impact wrench to tighten the bolt of special tool MB991237. It will break the special tool. 1. Install special tools MB991237 and MB991239 in the same manner as for removal, and compress the coil spring to install it to the shock absorber. 2. Align the edge of the coil spring to the stepped part of the shock absorber spring seat. >>B<< UPPER BRACKET ASSEMBLY INSTALLATION Install the upper bracket assembly so that the lower bushing inner pipe of the shock absorber is at the position shown. >>C<< JAM NUT INSTALLATION 1. Temporarily tighten the jam nut. CAUTION: Do not use an impact wrench to tighten the jam nut, otherwise the jam nut will be damaged. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 4685 2. Remove special tools MB991237 and MB991239, and then tighten the jam nut to 23 ± 2 Nm (17 ± 1 ft. lbs.). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 4686 Suspension Strut / Shock Absorber: Service and Repair Strut Assembly STRUT ASSEMBLY REMOVAL AND INSTALLATION CAUTION: For vehicles with ABS, be careful when handling the pole piece at the tip of the speed sensor so as not to damage it by striking against other parts. REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 4687 DISASSEMBLY SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 4688 2. Use special tool MB991176 to secure the strut, and then remove the jam nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 4689 4. Using special tool M13991176, tighten the jam nut to 64 ± 5 Nm (47 ± 4 ft. lbs.). INSPECTION - Check the bearing for wear or rust. - Check the rubber parts for damage or deterioration. - Check the spring for deformation, deterioration or damage. - Check the shock absorber for deformation. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications Trailing Arm Assembly To Body Nut 109 +/- 7 ft. lbs. Trailing Arm Assembly To Knuckle Nut 94 +/- 7 ft. lbs. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 4693 Trailing Arm: Service and Repair TRAILING ARM ASSEMBLY REMOVAL AND INSTALLATION CAUTION: *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. INSTALLATION SERVICE POINT >>A<< STOPPER B/STOPPER A INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 4694 1. Install stopper B in the shown direction. 2. Install stopper A in the shown direction while checking that the notches on stopper A are engaged with the projections on the trailing arm bushing. INSPECTION - Check the bushings for wear and deterioration. - Check the trailing arm for bends or damage. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Nut ............................................................................................................................................... .............................. 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4699 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front Wheel Bearing Breakaway Torque Check INSPECTION WHEEL BEARING BREAKAWAY TORQUE CHECK 1. Install the special tools MB990998 and MB990326 to the front hub assembly and tighten the nut to the specified torque. Tightening torque: 226 ± 29 Nm (167 ± 21 ft. lbs.) 2. Measure the wheel bearing breakaway torque with special tools. Limit: 1.0 Nm (9 inch lbs.) or less 3. Wheel bearing breakaway torque must be under the limit value and there should be no roughness when rotating the hub. Wheel Bearing End Play Check WHEEL BEARING END PLAY CHECK 1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the end play while moving the hub in the axial direction. Limit: 0.05 mm (0.002 inch) 4. If end play exceeds the limit, replace the front hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4702 Wheel Bearing: Testing and Inspection Rear Rear Hub Rotary-Sliding Resistance Check REAR HUB ROTARY-SLIDING RESISTANCE CHECK 1. For vehicles with rear disc brakes, remove the Caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. After turning the hub a few times to seat the bearing, wind a rope around the hub bolt and turn the hub by pulling at a 90 degree angle with a spring balance. Measure to determine whether or not the rotary-sliding resistance of the rear hub is at the limit value. Limit:...............18 Nm (13 ft. lbs.) 4. If the rotary-sliding resistance exceeds the limit value, replace the rear hub assembly. Wheel Bearing End Play Check 1. For vehicles with rear disc brakes, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. Check the bearing's end play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is end play. Limit:................0.05 mm (0.002 inch) 4. If the play exceeds the limit value, replace the rear hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Ball Joint Pinch Bolt ............................................................................................................................. .................................. 108 ± 10 Nm (80 ± 7 ft. lbs.) Wheel Hub Mounting Bolts ........................................................................................................................................................... 88 ± Nm (65 ± 7 ft. lbs.) Axle Nut ........................................................................................................ ..................................................................... 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Axle Hub Assembly - Front / REMOVAL AND INSTALLATION CAUTION: For vehicles with ABS, be careful when handling the projection at the tip of the speed sensor so as not to damage it by striking against other parts. The front hub assembly should not be dissembled. When removing the front hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the front hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play. REMOVAL SERVICE POINTS << A >> DRIVE SHAFT NUT REMOVAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 4708 CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when drive shaft nut is loosened. << B >> TIE ROD END DISCONNECTION CAUTION Do not remove nut from ball joint but loosen it and use special tools instead to avoid possible damage to ball joint threads. Hang special tools with ropes to prevent them from failing. INSTALLATION SERVICE POINT >> A << DRIVE SHAFT NUT INSTALLATION CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when castle nut is loosened. 1. Direct the flat side of a washer to a drive shaft nut to install. 2. Tighten driveshaft nut fully with special tools. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 4709 Wheel Hub: Service and Repair Rear Axle Hub Assembly - Rear / REMOVAL AND INSTALLATION REMOVAL SERVICE POINTS << A >> CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 4710 << B > ABS ROTOR REMOVAL << C >> BACKING PLATE REMOVAL Remove the backing plate and suspend it. INSTALLATION SERVICE POINT >> A << ABS ROTOR INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information Vehicle Lifting: Technician Safety Information STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 4716 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 4717 Vehicle Lifting: Vehicle Damage Warnings STANDARD PROCEDURE - HOISTING RECOMMENDATIONS Refer to the Owner's Manual for emergency vehicle lifting procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST. Fig. 7 Correct Vehicle Lifting Locations Floor Jack When properly positioned, a floor jack can be used to lift a Ram Van or Wagon (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not attempt to lift a CNG Ram Van/Wagon with a floor jack positioned under: - Body side sill - Steering linkage component - Drive shaft - Engine or transmission oil pan - Fuel cylinder - Front suspension arm CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. Hoist A vehicle can be lifted with: A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7). WARNING: WHEN A SERVICE PROCEDURE REQUIRES THE REMOVAL OF THE REAR AXLE, FUEL CYLINDER OR SPARE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Technician Safety Information > Page 4718 TIRE; EITHER: - Place additional weight on the rear end of the vehicle - Attach the vehicle to the hoist - Place jack stands under the vehicle for support to prevent tipping when the center of balance changes A CNG Ram Van/Wagon can be lifted with: Twin post, chassis hoist - Twin post, wheel lift hoist - Ramp type, drive on hoist Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service Precautions > Page 4719 Vehicle Lifting: Service and Repair LIFTING, JACKING SUPPORT LOCATION FLOOR JACK CAUTION: Never support any point other than the specified one, or it will be deformed. - For lifting, put rubber or similar material between the side sill and rigid rack, or the side sill area will be damaged. POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations. CAUTION: When service procedures require removing rear suspension, fuel tank and spare tire, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravity changes. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications Tire Size 2.4L, 3.0L P205/60 R16 91H (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L P215/50 R17 90H (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Tread depth of tire Minimum 0.06 in. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Inflation Tires: Testing and Inspection Tire Inflation TIRE INFLATION PRESSURE CHECK NOTE: For information on the inflation pressure, refer to the label attached to the center pillar on the driver's side. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Inflation > Page 4725 Tires: Testing and Inspection Tread Wear Indicators TIRE WEAR CHECK Measure the tread depth of the tires. Minimum limit: 1.6 mm (0.06 inch) If the remaining tread depth is less than the minimum limit, replace the tire. NOTE: When the tread depth of the tires is reduced to 1.6 mm (0.06 inch) or less, wear indicators will appear. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 4730 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 4731 Wheels: Specifications Wheel Type 2.4L, 3.0L Steel type, aluminum type (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L Aluminum type (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Size 2.4L, 3.0L 16 x 6JJ (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L 17 x 6.5JJ (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Amount of wheel offset 2.4L, 3.0L 1.8 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L 1.8 in. (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Pitch circle diameter (PCD) 2.4L, 3.0L 4.50 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L 4.50 in. (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Spare Wheel Type 2.4L, 3.0L Steel type (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Size 2.4L, 3.0L 16 x 4T (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Amount of wheel offset 2.4L, 3.0L 1.8 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Pitch circle diameter (PCD) 2.4L, 3.0L 4.50 in. (Except D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 4732 3.0L (D62AHNPEL4C, D62AHRPEL4C, D62AHNPEL4D, D62AHRPEL4D) Wheel Runout (Radial runout) Steel Wheel 0.05 in. or less Aluminum wheel 0.04 in. or less Wheel Runout (Lateral runout) Steel Wheel 0.05 in. or less Aluminum wheel 0.04 in. or less Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 4733 Wheels: Service and Repair WHEEL AND TIRE INSTALLATION SERVICE POINT Tighten the wheel nut to the specified torque. Tightening torque: 98 ± 10 Nm (73 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Axle Nut ............................................................................................................................................... .............................. 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 4738 Wheel Bearing: Fluid Type Specifications Use Mopar Multi-Purpose Lubricant or equivalent. (labeled NGLI Grade 2 EP, GC-LB) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front Wheel Bearing Breakaway Torque Check INSPECTION WHEEL BEARING BREAKAWAY TORQUE CHECK 1. Install the special tools MB990998 and MB990326 to the front hub assembly and tighten the nut to the specified torque. Tightening torque: 226 ± 29 Nm (167 ± 21 ft. lbs.) 2. Measure the wheel bearing breakaway torque with special tools. Limit: 1.0 Nm (9 inch lbs.) or less 3. Wheel bearing breakaway torque must be under the limit value and there should be no roughness when rotating the hub. Wheel Bearing End Play Check WHEEL BEARING END PLAY CHECK 1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the end play while moving the hub in the axial direction. Limit: 0.05 mm (0.002 inch) 4. If end play exceeds the limit, replace the front hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 4741 Wheel Bearing: Testing and Inspection Rear Rear Hub Rotary-Sliding Resistance Check REAR HUB ROTARY-SLIDING RESISTANCE CHECK 1. For vehicles with rear disc brakes, remove the Caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. After turning the hub a few times to seat the bearing, wind a rope around the hub bolt and turn the hub by pulling at a 90 degree angle with a spring balance. Measure to determine whether or not the rotary-sliding resistance of the rear hub is at the limit value. Limit:...............18 Nm (13 ft. lbs.) 4. If the rotary-sliding resistance exceeds the limit value, replace the rear hub assembly. Wheel Bearing End Play Check 1. For vehicles with rear disc brakes, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brakes, remove the brake drum. 3. Check the bearing's end play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is end play. Limit:................0.05 mm (0.002 inch) 4. If the play exceeds the limit value, replace the rear hub assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Specifications Wheel Hub: Specifications Ball Joint Pinch Bolt ............................................................................................................................. .................................. 108 ± 10 Nm (80 ± 7 ft. lbs.) Wheel Hub Mounting Bolts ........................................................................................................................................................... 88 ± Nm (65 ± 7 ft. lbs.) Axle Nut ........................................................................................................ ..................................................................... 226 ± 29 Nm (167 ± 21 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Axle Hub Assembly - Front / REMOVAL AND INSTALLATION CAUTION: For vehicles with ABS, be careful when handling the projection at the tip of the speed sensor so as not to damage it by striking against other parts. The front hub assembly should not be dissembled. When removing the front hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the front hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play. REMOVAL SERVICE POINTS << A >> DRIVE SHAFT NUT REMOVAL Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 4747 CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when drive shaft nut is loosened. << B >> TIE ROD END DISCONNECTION CAUTION Do not remove nut from ball joint but loosen it and use special tools instead to avoid possible damage to ball joint threads. Hang special tools with ropes to prevent them from failing. INSTALLATION SERVICE POINT >> A << DRIVE SHAFT NUT INSTALLATION CAUTION: Do not apply pressure to wheel bearing by the vehicle weight to avoid possible damage when castle nut is loosened. 1. Direct the flat side of a washer to a drive shaft nut to install. 2. Tighten driveshaft nut fully with special tools. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 4748 Wheel Hub: Service and Repair Rear Axle Hub Assembly - Rear / REMOVAL AND INSTALLATION REMOVAL SERVICE POINTS << A >> CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 4749 << B > ABS ROTOR REMOVAL << C >> BACKING PLATE REMOVAL Remove the backing plate and suspend it. INSTALLATION SERVICE POINT >> A << ABS ROTOR INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence Wheel Fastener: Specifications Tightening Sequence Wheel Torque Sequence - Master Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Tightening Sequence > Page 4754 Wheel Fastener: Specifications Wheel Nut 73 +/- 7 ft. lbs. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front FRONT / HUB BOLT REPLACEMENT Required Special Tools: MB990767: End Yoke Holder MB991618: Hub Bolt Remover 1. Remove the caliper assembly and suspend it with wire so that it does not fall. 2. Remove the brake disc. 3. Use the special tools MB990767 and MB99161 to remove the hub bolts. 4. Install the plain washer to the new hub bolt, and install the bolt with a nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 4757 Wheel Fastener: Service and Repair Rear REAR / HUB BOLT REPLACEMENT Required Special Tools: MB990767: End Yoke Holder MB991618: Hub Bolt Remover 1. For vehicles with rear disc brakes, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brake, remove the brake drum. 3. Pull the hub bolt out using special tools MB990767 and MB991618. NOTE: For vehicles with drum brakes, the hub bolts should be removed near the retainer spring installation position in order to maintain enough clearance for removal. 4. Install the plain washer to the new hub bolt, and install the bolt with a nut. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Testing and Inspection > Page 4762 Air Conditioning Switch: Service and Repair Heater Control Assembly And A/C Switch - Removal And Installation REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Testing and Inspection > Page 4763 Insert a flat-tipped screwdriver into the control base clip from inner side, and then remove the cable by lifting the claw part of the clip. INSTALLATION SERVICE POINT >>A<< HEATER CONTROL ASSEMBLY INSTALLATION 1. Follow the steps below to install the air outlet changeover damper link cable. 1. Set the air outlet changeover control knob on the heater control assembly to the defroster position. 2. Set the air outlet changeover damper link of the heater/ cooler unit to the defroster position as shown in the illustration, and then connect the cable to the link pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 2. Follow the steps below to install the air mix damper lever cable. 1. Set the temperature control knob on the heater control assembly to the maximum hot position. 2. Set the air mix damper lever of the heater/cooler unit to the maximum hot position as shown in the illustration, and then connect the cable to the lever pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 3. After installation, ensure that each damper operates smoothly by operating the heater control assembly knob. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions Air Door Actuator / Motor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Air Door Actuator / Motor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 4790 Air Door Actuator / Motor: Testing and Inspection INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR CHECK CAUTION: Cut off the battery voltage when the damper is in the inside/outside air position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations View J Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions Ambient Temperature Sensor / Switch HVAC: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Ambient Temperature Sensor / Switch HVAC: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor: Customer Interest A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4825 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4826 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor: All Technical Service Bulletins A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4832 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4833 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 4834 Blower Motor: Locations Grounding Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 Blower Motor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 4858 Blower Motor: Testing and Inspection Blower Fan and Motor Check When battery voltage is applied between the terminals, check that the motor operates. Also, check that there is no abnormal noise. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Heater Unit, Heater Core, Blower Assembly, Evaporator Unit Blower Motor: Service and Repair Heater Unit, Heater Core, Blower Assembly, Evaporator Unit REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Heater Unit, Heater Core, Blower Assembly, Evaporator Unit > Page 4861 Blower Assembly And Resistor Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Blower Motor Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Page 4888 Blower Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor Resistor: Customer Interest A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4897 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4898 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Blower Motor Resistor: All Technical Service Bulletins A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4904 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 4905 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4906 Blower Motor Resistor: Testing and Inspection Standard Value RESISTOR CHECK Use an ohmmeter to measure the resistance between the terminals. Check that the measured value is at the standard value. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 4907 Blower Assembly And Resistor Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Application and ID Cabin Air Filter: Application and ID This vehicle is not equipped with a cabin air filter. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Ventilators Part 1 - Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair > Page 4917 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compressor Clutch: Initial Inspection and Diagnostic Overview Compressor Magnetic Clutch Operation Check Connect the positive battery terminal to the compressor magnetic clutch connector terminal 3, and ground the negative battery terminal to the body of the compressor. The condition is normal if the sound of the magnetic clutch (click) can be heard. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4923 Compressor Clutch: Component Tests and General Diagnostics MAGNETIC CLUTCH TEST 1. Disconnect the magnetic clutch connector to the magnetic clutch. 2. Connect positive battery voltage directly to the connector for the magnetic clutch. 3. If the magnetic clutch is normal, there will be "click." If the pullet and armature do not make contact ("click"), there is a malfunction. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 4924 Compressor Clutch: Service and Repair MAGNETIC CLUTCH Disassembly And Assembly DISASSEMBLY SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 4925 >>A<< CLUTCH COIL INSTALLATION When installing the clutch coil to the A/C compressor body, install so that the pin hole of the A/C compressor body and the clutch coil projection are aligned. >>B<< SNAP RING INSTALLATION Install the snap ring so that the tapered surface is to the outside. >>C<< ARMATURE PLATE INSTALLATION Align the serration protrusion on the crankshaft with the notch on the armature and install. >>D<< NUT INSTALLATION Use special tools MB991367 and MB991386 to hold the magnetic clutch, and tighten the nut in the same manner as for removal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 4926 >>E<< AIR GAP ADJUSTMENT Check whether or not the air gap of the clutch is within the standard value. Standard value: - <2.4L engine> 0.3 - 0.5 mm (0.012 - 0.020 inch) - <3.0L engine> 0.4 - 0.6 mm (0.016 - 0.024 inch) NOTE: If there is a deviation of the air gap from the standard value, make the necessary adjustment by adjusting the number of shims. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair Compressor Pulley: Service and Repair COMPRESSOR ASSEMBLY AND TENSION PULLEY Compressor Assembly And Tension Pulley - Removal And Installation REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair > Page 4930 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair > Page 4931 NOTE: When replacing the following parts at the same times as the compressor; subtract the rated oil amount of the each part from Y cu.cm (Y floz) and discharge from the new compressor. Quantity: Evaporator: 60 cu.cm (2.0 floz) - Condenser: 15 cu.cm (0.5 floz) - Suction hose: 10 cu.cm (0.3 floz) - Receiver: 10 cu.cm (0.3 floz) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 4935 A/C Compressor Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Speed Sensor, HVAC > Component Information > Testing and Inspection Compressor Speed Sensor: Testing and Inspection Revolution Pick-up Sensor Check Measure the resistance between terminals 1 and 3. Check that the measured value is at the standard value. Standard value: 405 ± 35 Ohm when the ambient temperature is 20 °C (68 °F) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair CONDENSER AND CONDENSER FAN MOTOR Condenser And Condenser Fan Motor - Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Testing and Inspection Condenser Fan Motor: Testing and Inspection Condenser Fan Motor Check Check to be sure that the condenser fan motor operates when battery voltage is applied to terminal 2 and terminal 1 grounded. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Testing and Inspection > Page 4946 Condenser Fan Motor: Service and Repair CONDENSER AND CONDENSER FAN MOTOR Condenser And Condenser Fan Motor - Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection Fan Control Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Mode/Temperature Lever Service Control Assembly: Technical Service Bulletins A/C - Mode/Temperature Lever Service NUMBER: 24-019-05 GROUP: Heating & A/C DATE: November 1, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 24-002-01, DATED FEBRUARY 16, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND A REVISED DISCUSSION. SUBJECT: HVAC Mode And Temperature Lever Service OVERVIEW: This bulletin describes new parts that are available for HVAC service. MODELS: 2001 - **2005** (ST) Sebring/Stratus Coupe DISCUSSION: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Mode/Temperature Lever Service > Page 4954 The mode (Fig. 1) and temperature (Fig. 2) linkage levers have been made available as service components for the HVAC assembly. If either lever is broken or damaged, the linkage levers can be replaced separately as compared to replacing the HVAC assembly. To replace either lever, remove the cable from the lever and HVAC case attachment, remove the lever mounting screw and secure the new lever in place of the broken one. NOTE: THE FLOOR DUCT MUST BE SET ASIDE TO GAIN ACCESS TO THE MODE LEVER. PULL THE DUCT OUT AND ROTATE IT ON THE ATTACHING RIVET. **Follow the adjustment procedures outlined in TechCONNECT, under: Service Info, 24-Heating And Air Conditioning, Heater Control Assembly And A/C Switch, Installation Service Points.** Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Mode/Temperature Lever Service > Page 4955 PARTS REQUIRED: TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 Control Assembly: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4979 Control Assembly: Service and Repair Heater Control Assembly And A/C Switch - Removal And Installation REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 4980 Insert a flat-tipped screwdriver into the control base clip from inner side, and then remove the cable by lifting the claw part of the clip. INSTALLATION SERVICE POINT >>A<< HEATER CONTROL ASSEMBLY INSTALLATION 1. Follow the steps below to install the air outlet changeover damper link cable. 1. Set the air outlet changeover control knob on the heater control assembly to the defroster position. 2. Set the air outlet changeover damper link of the heater/ cooler unit to the defroster position as shown in the illustration, and then connect the cable to the link pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 2. Follow the steps below to install the air mix damper lever cable. 1. Set the temperature control knob on the heater control assembly to the maximum hot position. 2. Set the air mix damper lever of the heater/cooler unit to the maximum hot position as shown in the illustration, and then connect the cable to the lever pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 3. After installation, ensure that each damper operates smoothly by operating the heater control assembly knob. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations Control Module HVAC: Locations Overall View View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Control Module HVAC: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5015 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5016 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5017 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5018 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5019 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5020 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5021 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5022 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5023 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5024 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5025 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5026 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5032 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5033 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5034 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5035 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5036 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5037 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5038 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5039 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5040 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5041 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5042 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5043 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5044 Evaporator Core: Service and Repair REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations View X Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Technical Service Bulletins > A/C - Compressor High Pressure Valve Replacement Technical Service Bulletin # 24-006-03 Date: 030725 A/C - Compressor High Pressure Valve Replacement NUMBER: 24-006-03 GROUP: Heating & A/C DATE: July 25, 2003 SUBJECT: A/C High Pressure (HP) Relief Valve Available OVERVIEW: This bulletin involves replacing the A/C HP relief valve instead of the compressor assembly if necessary. MODELS: 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe SYMPTOM/CONDITION: The high pressure relief valve on the A/C compressor has been made available as a service part. If the valve requires replacement, there is no need to replace the complete compressor assembly. The valve can be serviced separately. Please see diagnosis procedure below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Technical Service Bulletins > A/C - Compressor High Pressure Valve Replacement > Page 5055 DIAGNOSIS: PARTS REQUIRED: EQUIPMENT REQUIRED: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Technical Service Bulletins > A/C - Compressor High Pressure Valve Replacement > Page 5056 SERVICE PART KIT Two different types (gold or silver color) of high pressure relief valves were used on the affected vehicles. Both valves will be included in service part kit MN177247. When replacing the valve, the dealer technician must confirm the color of the valve (Fig. 2) on the vehicle and then select the same colored valve from the kit. NOTE: The two valves are different sizes and cannot be interchanged. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure 1. Use the refrigerant recovery unit to remove the refrigerant from the system. NOTE: Refer to the refrigerant recovery and recycling unit instruction manual for operation of the unit. 2. Raise the vehicle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Technical Service Bulletins > A/C - Compressor High Pressure Valve Replacement > Page 5057 3. Remove 3 bolts and 3 push pins in order to remove the right front fender inner lower splash shield (Fig. 3). 4. Remove the drive belt. Refer to the service information available in TechCONNECT or the 2003 Sebring/Stratus Coupe Service Manual, Volume 4 (Publication No. 81-270-03031D) page 24-39. 5. Remove the suction hose from the A/C compressor. CAUTION: Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapor easily, possibly damaging the compressor and deteriorating performance. Plug the disconnected hoses and compressor openings to prevent foreign matter from getting into the system. 6. Remove the discharge hose from the A/C compressor. 7. Unplug the compressor clutch wiring connector. 8. Remove the four A/C compressor mounting bolts. CAUTION: When removing the compressor, be careful not to spill the compressor oil. 9. Remove the A/C compressor and place it on a suitable bench. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Technical Service Bulletins > A/C - Compressor High Pressure Valve Replacement > Page 5058 10. Remove the wiring connector bracket fastener and reposition out of the way. 11. Remove the pressure relief valve (Fig. 2). 12. Select the correct pressure relief valve from the replacement package. 13. Install the correct pressure relief valve. Torque the pressure relief valve to 12 Nm (106.2 in. lbs.). 14. Install the wiring connector bracket. 15. Before installing the compressor on the vehicle, fill it with compressor oil according to the following procedure. a. Measure the amount of oil in the removed compressor [X cm3 (X floz)]. b. Use the formula to calculate the amount of oil necessary to replace the amount that was lost through the relief valve operation [Y cm3 (Y fl oz.)]. Then, refill the compressor with that amount of oil and install the compressor on the vehicle. NOTE: New compressor oil amount formula = 140 CM3 (3.4 FLOZ) 140 CM3 - X CM3 = Y CM3 (3.4 FLOZ - X FLOZ = Y FLOZ) NOTE: Y CM3 (Y floz) stands for the amount of oil used up due to the relief valve operation. 16. Install the compressor. 17. Install the four A/C compressor mounting bolts. Torque the mounting bolts to 25 Nm (18 ft. lbs.). 18. Plug the wiring harness connector into the compressor clutch wiring connector. 19. Using a new 0 ring, p/n MR117263, install A/C suction line on compressor. Torque the anchor bolt to 25 Nm (18 ft. lbs.). 20. Using a new 0 ring, p/n MR117054, install A/C discharge line on compressor. Torque the anchor bolt to 25 Nm (18 ft. lbs.). 21. Install the accessory drive belt. 22. Adjust the drive belt tension. Refer to the service information available in TechCONNECT or the 2003 Sebring/Stratus Coupe Service Manual, Volume 1 (Publication No. 81-270-030310) page 0-14 and 0-15. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Technical Service Bulletins > A/C - Compressor High Pressure Valve Replacement > Page 5059 23. Install the lower splash shield. 24. Lower the vehicle. 25. Use the refrigerant recovery and recycling unit, refill the A/C system with .91 - .95 lbs. (14.6 15.3 oz.) of R134A refrigerant. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair Hose/Line HVAC: Service and Repair Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation Housing Assembly HVAC: Customer Interest A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 5071 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C - Erratic Blower Motor Operation > Page 5072 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C Erratic Blower Motor Operation Housing Assembly HVAC: All Technical Service Bulletins A/C - Erratic Blower Motor Operation NUMBER: 24-001-05 GROUP: Heating & A/C DATE: February 1, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL FEBRUARY 14, 2005. SUBJECT: Blower Motor Does Not Run On Every Speed OVERVIEW: This bulletin involves modifying the HVAC housing and installing a revised blower motor resistor. MODELS: 2000 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan NOTE: MODEL YEAR WAS UPDATED FROM 2001-2004 RANGE TO 2000-2004 RANGE PER UPDATE FROM CHRYSLER WEBSITE. SYMPTOM/CONDITION: The blower motor does not run on every speed because the blower motor resistor has failed. DIAGNOSIS: If the vehicle operator describes the above Symptom, perform the Repair Procedure PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the resistor to cool before performing diagnosis or service. Failure to take this precaution can result in personal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer panel from right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - REMOVAL). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C Erratic Blower Motor Operation > Page 5078 3. Disconnect the wire harness connector from the blower motor resistor (Fig. 1). 4. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor. 5. Use a hot knife or similar tool to the enlarge the blower resistor opening in the HVAC housing so that the opening matches the inside edge of raised rib around the opening, (Fig. 2). NOTE: Remove any/all debris from the HVAC housing. 6. Position the blower motor resistor into the bottom of the HVAC housing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-001-05 > Feb > 05 > A/C Erratic Blower Motor Operation > Page 5079 7. Install the two screws that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2 Nm (17 in.lbs.). 8. Connect the wire harness connector to the blower motor resistor. 9. Install the silencer panel to the right side of the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL/RIGHT IP SILENCER PANEL - INSTALLATION). 10. Reconnect the negative battery cable. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Page 5080 Housing Assembly HVAC: Service and Repair REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Testing and Inspection Receiver Dryer: Testing and Inspection RECEIVER DRIER TEST Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet. If there is a difference in the temperatures, the receiver drier is restricted. Replace the receiver drier. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity Refrigerant Capacity 14.6 - 15.3 oz (415 - 435 g) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5088 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. .......................................................................... 134a Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5089 Refrigerant: Service Precautions R-134a - R-12 Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Ozone filters out harmful radiation from the sun. To assist in protecting the ozone layer, Chrysler Corporation recommends an R-134a refrigerant recycling device. The Clean Air Act Amendment of 1990 requires that Freon be recovered when accessing the air conditioning circuit and that technicians hold a refrigerant recovery and handling certification. The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451 Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Fax: 215-541-4635 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5090 http://www.macsw.org/ Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5091 Refrigerant: Testing and Inspection REFRIGERANT LEVEL TEST Use the refrigerant recovery station to remove all of the refrigerant, and then calculate the amount of the refrigerant and charge it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacities Refrigerant Oil Capacities 4.1 fl oz (120 cm3) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5096 Refrigerant Oil: Fluid Type Specifications SUN PAG 56 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5097 Refrigerant Oil: Service and Repair REFILLING OF OIL IN THE A/C SYSTEM Too little oil will provide inadequate compressor lubrication and cause a. compressor failure. Too much oil will increase discharge air temperature. When a compressor is installed at the factory, it contains 120 cu. cm (4.1 floz) of refrigerant oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant. Some of this oil will be trapped and retained in various parts of the system. When the following system components are changed, it is necessary to add oil to the system to replace the oil being removed with the component. Compressor oil: SUN PAG 56 Quantity: - Evaporator: 60 cu.cm (2.0 floz) - Condenser: 15 cu.cm (0.5 floz) - Suction hose: 10 cu.cm (0.3 floz) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Overall View Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions Refrigerant Pressure Sensor / Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 Refrigerant Pressure Sensor / Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5124 Refrigerant Pressure Sensor / Switch: Testing and Inspection PRESSURE SWITCH CHECK 1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the harness side as shown in the illustration. 2. Install a gauge manifold to the high-pressure side service valve of the refrigerant line. 3. When the high/low pressure sides of the dual pressure switch are at operation pressure (ON) and there is continuity between the respective terminals, then the condition is normal. If there is no continuity, replace the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Locations Refrigerant Temperature Sensor: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Locations > Page 5128 Refrigerant Temperature Sensor: Testing and Inspection Refrigerant Temperature Switch Check When the A/C is off, check that there is continuity between the refrigerant-temperature switch terminals. If not, replace the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Blower Motor Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 Blower Motor Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Page 5156 Blower Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 5160 A/C Compressor Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection Fan Control Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Control Module HVAC: Locations Overall View View F Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Module HVAC: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Control Module HVAC: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection > Page 5194 Air Conditioning Switch: Service and Repair Heater Control Assembly And A/C Switch - Removal And Installation REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Testing and Inspection > Page 5195 Insert a flat-tipped screwdriver into the control base clip from inner side, and then remove the cable by lifting the claw part of the clip. INSTALLATION SERVICE POINT >>A<< HEATER CONTROL ASSEMBLY INSTALLATION 1. Follow the steps below to install the air outlet changeover damper link cable. 1. Set the air outlet changeover control knob on the heater control assembly to the defroster position. 2. Set the air outlet changeover damper link of the heater/ cooler unit to the defroster position as shown in the illustration, and then connect the cable to the link pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 2. Follow the steps below to install the air mix damper lever cable. 1. Set the temperature control knob on the heater control assembly to the maximum hot position. 2. Set the air mix damper lever of the heater/cooler unit to the maximum hot position as shown in the illustration, and then connect the cable to the lever pin. 3. Push the outer cable in the direction so that there is no looseness, and then secure it with the clip. 3. After installation, ensure that each damper operates smoothly by operating the heater control assembly knob. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations View J Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions Ambient Temperature Sensor / Switch HVAC: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 Ambient Temperature Sensor / Switch HVAC: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5214 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5215 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5216 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5217 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5218 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5219 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5220 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5221 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Compressor Speed Sensor, HVAC > Component Information > Testing and Inspection Compressor Speed Sensor: Testing and Inspection Revolution Pick-up Sensor Check Measure the resistance between terminals 1 and 3. Check that the measured value is at the standard value. Standard value: 405 ± 35 Ohm when the ambient temperature is 20 °C (68 °F) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations View X Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Overall View Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions Refrigerant Pressure Sensor / Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 Refrigerant Pressure Sensor / Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 5257 Refrigerant Pressure Sensor / Switch: Testing and Inspection PRESSURE SWITCH CHECK 1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the harness side as shown in the illustration. 2. Install a gauge manifold to the high-pressure side service valve of the refrigerant line. 3. When the high/low pressure sides of the dual pressure switch are at operation pressure (ON) and there is continuity between the respective terminals, then the condition is normal. If there is no continuity, replace the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Locations Refrigerant Temperature Sensor: Locations Overall View View C Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Locations > Page 5261 Refrigerant Temperature Sensor: Testing and Inspection Refrigerant Temperature Switch Check When the A/C is off, check that there is continuity between the refrigerant-temperature switch terminals. If not, replace the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ventilation Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Heating and Air Conditioning > Ventilation Switch > Component Information > Testing and Inspection Blower Switch Assembly Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System SERVICE OF DEPLOYED AIRBAG DRIVER AIRBAG After a Driver Airbag has been deployed: - Driver Airbag - Steering Wheel - Clock Spring - Steering Column assembly The component above must be replaced because they cannot be reused. Replace any other driver airbag system components if damaged. PASSENGER AIRBAG After a Passenger Airbag has been deployed: - Passenger Airbag - Instrument Panel and Pad Assembly The components above must be replaced because of visible or non visible structural damage. The glove box, top cover, cluster hood, steering column cover, right trim bezel and/or end cap, or any other components should be checked and replaced if damaged. CLEAN UP Roll or fold the Airbag towards the instrument panel surface or steering wheel and tape the door shut or the bag to the steering wheel. Use a vacuum cleaner to remove any residual powder from the vehicle interior. Work from the outside in to avoid kneeling or sitting in a contaminated area. Vacuum the heater and A/C outlets as well. If the heater or air conditioner was in RECIRC mode at time of airbag deployment, operate blower motor on low speed and vacuum powder residue expelled from the heater and A/C outlets. Multiple vacuum cleaning may to necessary to decontaminate the interior of the vehicle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5273 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Testing and Inspection Air Bag: Testing and Inspection AIR BAG MODULE CHECK WARNING: - If any component damage is found during the following inspection, replace the air bag module with a new one. Dispose of the old one according to the specified procedure. - Never attempt to measure the circuit resistance of the air bag modules (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester accidental air bag deployment will result in serious personal injury. 1. Check the pad cover for dents, cracks or deformation. 2. Check the connectors for damage, the terminals for deformation, and the harness for binds. 3. Check the air bag inflator case for dents, cracks or deformation. 4. Install the air bag module (driver's side) to the steering wheel and check fit and alignment with the wheel. 5. Install the air bag module (passenger's side) to the instrument pane and crossmember, and check fit and alignment. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag Air Bag: Service and Repair Driver Airbag AIR BAG MODULES AND CLOCK SPRING WARNING: - Never attempt to disassemble or repair the air bag modules or the clock spring. If faulty, replace the part. - Do not drop the air bag modules or the clock spring or allow contact with water, grease or oil. Replace it if a dent, crack, deformation or rust is detected. - The air bag modules should be stored on a flat surface with the pad cover facing upward. Do not place anything on top of it. - Do not expose the air bag modules to temperatures over 93 °C (200 °F). - After deployment of an air bag, replace the clock spring with a new one. - Wear gloves and safety glasses when handling air bags that have already deployed - An undeployed air bag module should only be disposed of in accordance with the procedures. For removal and installation of the front seatback assembly with side-airbag module, refer to Front Seat Assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5283 Air Bag Module (driver's Side), Clock Spring - Removal And Installation REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5284 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5285 <> STEERING WHEEL REMOVAL CAUTION: Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism. Using the special tool MB990803, remove the steering wheel. <> CLOCK SPRING REMOVAL WARNING: The removed clock spring should be stored in a clean and dry place. <> AIR BAG MODULE REMOVAL (PASSENGER'S SIDE) WARNING: The removed air bag module should be stored in a clean and dry place with the pad cover face up. INSTALLATION SERVICE POINTS >>A<< PRE-INSTALLATION INSPECTION WARNING: Dispose of air bag modules only according to the specified procedure. 1. When installing the new air bag modules and clock spring, refer to "INSPECTION". 2. Connect the negative (-) battery cable. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition, switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 3. Connect scan tool MB991502 to the data link connector. 4. Turn the ignition switch to the "ON" position. 5. Conduct diagnostic test using scan tool MB991502 to ensure entire SRS operates properly. DANGER: Wait at least 60 seconds after disconnecting the battery cable before doing any further work. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. 6. Turn the ignition switch to the "LOCK" (OFF) position. Disconnect the negative (-) battery cable and tape the terminal to prevent accidental connection and air bags deployment. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5286 >>B<< CLOCK SPRING INSTALLATION WARNING: Ensure that the clock spring's mating marks are properly aligned. If not, the steering wheel may not rotate completely during a turn, or the flat cable in the clock spring could be damaged. This would prevent normal SRS operation and possibly cause serious injury to the driver. Align the mating marks of the clock spring. Turn the front wheels to the straight-ahead position. Then install the clock spring to the column switch. Turn the clock spring clockwise fully. Then turn it back approximately 3 3/4 turns counterclockwise to align the mating marks. >>C<< STEERING WHEEL INSTALLATION CAUTION: When installing the steering wheel, ensure that the harness of the clock spring does not become caught or tangled. 1. Before installing the steering wheel, turn the vehicle's front wheels to the straight-ahead position and align the mating marks of the clock spring. 2. After securing the steering wheel, turn the steering wheel all the way in both directions to confirm that the steering wheel rotation is normal. >>D<< AIR BAG MODULE INSTALLATION (DRIVER'S SIDE) CAUTION: If there is gap at place B shown in the illustration, that means the connector is not firmly inserted, i.e. not correctly connected. In such a case, insert connector to the place, where there remains no gap at place B shown in the illustration. 1. Connect the clock spring connector securely. 2. Tighten the air bag module mounting screws to 9.0 ± 2.0 N.m (78 ± 17 in-lb) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5287 >>E<< POST-INSTALLATION INSPECTION 1. Reconnect the negative (-) battery cable. 2. Turn the ignition switch to the "ON" position. 3. Does the "SRS" warning light illuminate for approximately seven seconds, and go out? 4. If yes, the SRS system is functioning properly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5288 Air Bag: Service and Repair Passenger Airbag AIR BAG MODULES AND CLOCK SPRING WARNING: - Never attempt to disassemble or repair the air bag modules or the clock spring. If faulty, replace the part. - Do not drop the air bag modules or the clock spring or allow contact with water, grease or oil. Replace it if a dent, crack, deformation or rust is detected. - The air bag modules should be stored on a flat surface with the pad cover facing upward. Do not place anything on top of it. - Do not expose the air bag modules to temperatures over 93 °C (200 °F). - After deployment of an air bag, replace the clock spring with a new one. - Wear gloves and safety glasses when handling air bags that have already deployed - An undeployed air bag module should only be disposed of in accordance with the procedures. For removal and installation of the front seatback assembly with side-airbag module, refer to Front Seat Assembly. REMOVAL SERVICE POINTS Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5289 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5290 <> STEERING WHEEL REMOVAL CAUTION: Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism. Using the special tool MB990803, remove the steering wheel. <> CLOCK SPRING REMOVAL WARNING: The removed clock spring should be stored in a clean and dry place. <> AIR BAG MODULE REMOVAL (PASSENGER'S SIDE) WARNING: The removed air bag module should be stored in a clean and dry place with the pad cover face up. INSTALLATION SERVICE POINTS >>A<< PRE-INSTALLATION INSPECTION WARNING: Dispose of air bag modules only according to the specified procedure. 1. When installing the new air bag modules and clock spring, refer to "INSPECTION". 2. Connect the negative (-) battery cable. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition, switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502. 3. Connect scan tool MB991502 to the data link connector. 4. Turn the ignition switch to the "ON" position. 5. Conduct diagnostic test using scan tool MB991502 to ensure entire SRS operates properly. DANGER: Wait at least 60 seconds after disconnecting the battery cable before doing any further work. WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. 6. Turn the ignition switch to the "LOCK" (OFF) position. Disconnect the negative (-) battery cable and tape the terminal to prevent accidental connection and air bags deployment. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5291 >>B<< CLOCK SPRING INSTALLATION WARNING: Ensure that the clock spring's mating marks are properly aligned. If not, the steering wheel may not rotate completely during a turn, or the flat cable in the clock spring could be damaged. This would prevent normal SRS operation and possibly cause serious injury to the driver. Align the mating marks of the clock spring. Turn the front wheels to the straight-ahead position. Then install the clock spring to the column switch. Turn the clock spring clockwise fully. Then turn it back approximately 3 3/4 turns counterclockwise to align the mating marks. >>C<< STEERING WHEEL INSTALLATION CAUTION: When installing the steering wheel, ensure that the harness of the clock spring does not become caught or tangled. 1. Before installing the steering wheel, turn the vehicle's front wheels to the straight-ahead position and align the mating marks of the clock spring. 2. After securing the steering wheel, turn the steering wheel all the way in both directions to confirm that the steering wheel rotation is normal. >>D<< AIR BAG MODULE INSTALLATION (DRIVER'S SIDE) CAUTION: If there is gap at place B shown in the illustration, that means the connector is not firmly inserted, i.e. not correctly connected. In such a case, insert connector to the place, where there remains no gap at place B shown in the illustration. 1. Connect the clock spring connector securely. 2. Tighten the air bag module mounting screws to 9.0 ± 2.0 N.m (78 ± 17 in-lb) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Airbag > Page 5292 >>E<< POST-INSTALLATION INSPECTION 1. Reconnect the negative (-) battery cable. 2. Turn the ignition switch to the "ON" position. 3. Does the "SRS" warning light illuminate for approximately seven seconds, and go out? 4. If yes, the SRS system is functioning properly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Overall View View H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5298 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5299 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5300 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5301 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5302 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5303 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5304 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5305 Air Bag Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5306 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5307 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5308 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5309 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5310 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5311 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5312 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5313 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5314 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5315 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 5319 Air Bag Control Module: Testing and Inspection FRONT SEATBACK ASSEMBLY WITH SIDE-AIRBAG MODULE CHECK WARNING: - If any improper part is found during the following inspection, replace the front seatback assembly with a new one. Dispose of the old one according to the specified procedure. - Never attempt to measure the circuit resistance of the side-airbag module (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental side-airbag deployment will result in serious personal injury. 1. Check the side-airbag module deployment section for dents or deformation. 2. Check the connector for damage, the terminals for deformation, and the harness for binds. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 5320 Air Bag Control Module: Service and Repair Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 5321 >>A<< SRS-ECU INSTALLATION WARNING: The SRS may not activate if the SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle's driver or front passenger. >>B< Check the head mark "E" on the bolt and attach the grounding bolt. >>C<< POST-INSTALLATION INSPECTION 1. Reconnect the negative (-) battery cable. 2. Turn the ignition switch to the "ON" position. 3. Does the "SRS" warning light illuminate for approximately seven seconds, and then go out? 4. If yes, the SRS system is functioning properly. If no. INSPECTION WARNING: If a dent, crack, deformation or rust is discovered, replace the SRS-ECU with a new one. - Check the SRS-ECU and brackets for dents, cracks or deformation. - Check the SRS-ECU connector for damage, and the terminals for deformation. NOTE: Refer inspection of SRS-ECU for other than physical damage. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications Service Specification Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 5325 Clockspring Assembly / Spiral Cable: Testing and Inspection CLOCK SPRING CHECK Required Special Tools: - MB991613: SRS Check Harness - MB991223 (MB991222): Harness Set (Probe) If any malfunction is found in steps 1 through 4, replace the clock spring with a new one. 1. Check the connectors and protective tube for damage, and the terminals for deformation. 2. Visually check the case for damage. 3. Align the paint mark of special tool MB991613 connector number 4 with the notch in clock spring connector number 2 (arrow in the illustration) to connect the connectors number 2 and 4. 4. Measure the resistance between the terminals 22 and 23 of special tool MB991613 connector number 5. Standard value: less than 0.4 ohm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations View e Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5329 Impact Sensor: Service and Repair SIDE IMPACT SENSOR A side impact sensor is installed behind the quarter trim on both driver and passenger sides of the vehicle. Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5330 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5331 WARNING: If a dent, crack, deformation or rust is detected, replace with a new sensor. NOTE: For checking of the side impact sensor other than described below, refer to the section concerning SRS diagnosis. 1. Check the side impact sensor and bracket for dents, cracks or deformation. 2. Check the connector for damage, and terminal for deformation. 3. Check that there is no bending or corrosion in the quarter panel. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Overall View View H Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 Air Bag Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 5359 Air Bag Control Module: Testing and Inspection FRONT SEATBACK ASSEMBLY WITH SIDE-AIRBAG MODULE CHECK WARNING: - If any improper part is found during the following inspection, replace the front seatback assembly with a new one. Dispose of the old one according to the specified procedure. - Never attempt to measure the circuit resistance of the side-airbag module (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental side-airbag deployment will result in serious personal injury. 1. Check the side-airbag module deployment section for dents or deformation. 2. Check the connector for damage, the terminals for deformation, and the harness for binds. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 5360 Air Bag Control Module: Service and Repair Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 5361 >>A<< SRS-ECU INSTALLATION WARNING: The SRS may not activate if the SRS-ECU is not installed properly, which could result in serious injury or death to the vehicle's driver or front passenger. >>B< Check the head mark "E" on the bolt and attach the grounding bolt. >>C<< POST-INSTALLATION INSPECTION 1. Reconnect the negative (-) battery cable. 2. Turn the ignition switch to the "ON" position. 3. Does the "SRS" warning light illuminate for approximately seven seconds, and then go out? 4. If yes, the SRS system is functioning properly. If no. INSPECTION WARNING: If a dent, crack, deformation or rust is discovered, replace the SRS-ECU with a new one. - Check the SRS-ECU and brackets for dents, cracks or deformation. - Check the SRS-ECU connector for damage, and the terminals for deformation. NOTE: Refer inspection of SRS-ECU for other than physical damage. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Locations Seat Belt: Locations View e Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Reminder Buzzer: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 Seat Belt Reminder Buzzer: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Seat Belt Reminder Buzzer: Electrical Diagrams Seat Belt Tone Alarm Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Seat Belt Tone Alarm Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 Seat Belt Reminder Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Page 5421 Seat Belt Reminder Lamp: Description and Operation SEAT BELT WARNING LIGHT If the driver turns the ignition switch to the "ON" position without wearing the seat belt, the seat belt warning light illuminates to alert the driver to wear the seat belt. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations View e Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5426 Impact Sensor: Service and Repair SIDE IMPACT SENSOR A side impact sensor is installed behind the quarter trim on both driver and passenger sides of the vehicle. Removal And Installation REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5427 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5428 WARNING: If a dent, crack, deformation or rust is detected, replace with a new sensor. NOTE: For checking of the side impact sensor other than described below, refer to the section concerning SRS diagnosis. 1. Check the side impact sensor and bracket for dents, cracks or deformation. 2. Check the connector for damage, and terminal for deformation. 3. Check that there is no bending or corrosion in the quarter panel. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair Antenna Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Alarm Horn Relay > Component Information > Locations Alarm Horn Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Overall View View G Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 Keyless Entry: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Keyless Entry: Electrical Diagrams Central Door Locking System Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Central Door Locking System Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Central Door Locking System Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Central Door Locking System Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Central Door Locking System Part 5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 Central Door Locking System Part 6 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Central Door Locking System Part 7 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Central Door Locking System Part 8 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Central Door Locking System Part 8 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Central Door Locking System Part 10 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Central Door Locking System Part 11 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Central Door Locking System Part 12 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 Central Door Locking System Part 13 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Diagrams > Page 5479 Keyless Entry: Description and Operation GENERAL DESCRIPTION OPERATION KEYLESS ENTRY SYSTEM Some models are equipped with a radio-controlled keyless entry system. The main features are: - Antenna and receiver are incorporated in the ETACS-ECU. - ID code can be registered by using the scan tool (MUT- II). - Transmitter is a key holder type, which incorporates lock switch, unlock switch, trunk switch and panic switch. - The locking is answered back by two times' flashing of the dome light, two times' flashing of the turn signal light and one time blowing of the horn. - The unlocking is answered back by lighting of the dome light for 15 seconds and one time flashing of the turn signal light. KEYLESS ENTRY SYSTEM OPERATION Keyless Entry Answerback Function If the RKE transmitter "LOCK" or "UNLOCK" switch is pressed while the ignition key is removed, the doors can be locked or unlocked. If the doors are closed, the hazard warning lights, the interior lights and the horn will operate due to answerback function. Because of the answerback function, the hazard warning lights flash twice, and the horn sounds once, the interior lights flashes twice when the doors are locked. Meanwhile, when the doors are unlocked, the hazard warning lights flash and the interior lights illuminates for 30 seconds. The hazard and the horn answerback functions can be cancelled by using the transmitter. Keyless Entry Room Lamp Answerback Interior lights's answerback operation in response to door lock control by keyless entry system: To allow the driver to confirm the doors have locked by the keyless entry system, the ETACS-ECU causes the interior lights to blink twice when the doors are locked by the RKE system and to illuminate for approximately 30 seconds when the doors are locked. The interior lights' answerback operation in response to a keyless entry system control action is accompanied by flashing of the hazard warning lights. Trunk Lid Opener Function After "TRUNK" switch of the transmitter is pushed "ON" twice within 5 seconds without ignition key in the key hole, ETAGS-ECU makes trunk lid opener actuator open the trunk lid. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery Keyless Entry: Service and Repair How to Replace the Transmitter Battery HOW TO REPLACE THE TRANSMITTER BATTERY CAUTION: Do not allow water or dust stick to enter the inside of the transmitter when it is open. Also, do not touch the precision electronic device. 1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+) side face-down. Battery required for replacement: Coin type battery CR2032 3. Insert the claw first and assemble the transmitter. 4. Verify that the keyless entry system operates. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5482 Keyless Entry: Service and Repair Keyless Entry System Timer Lock Function Inspection KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION Attempt to unlock the doors by using the transmitter. If the doors are not locked within 30 seconds, carry out troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5483 Keyless Entry: Service and Repair Enabling/Disabling the Answerback Function ENABLING DISABLING THE ANSWERBACK FUNCTION If the keyless entry system locks or unlocks the doors, the dome light flashes or illuminates, the hazard warning light flashes (hazard answer back function) and the horn sounds (horn answer back function). The hazard and horn answer back functions can be enabled or disabled according to the following procedure: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5484 Keyless Entry: Service and Repair Enabling/Disabling the Hazard Answerback Function The hazard answer back function can be enabled or disabled by one of the two following procedure 1. Enter the hazard answerback customize mode by observing one of the following steps. If the ETACS-ECU enters the customize mode, its tone alarm will sound once. 1. Turn the ignition switch to the LOCK (OFF) position. 2. Turn off the hazard warning light switch. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting scan tool MB991502. 3. Connect scan tool MB991502 to the data link connector terminal (1). 4. Close the driver's side door. 5. Keep the windshield washer switch on for at least ten seconds. Then the ETACS-ECU tone alarm will sound once. 2. If the transmitter LOCK switch is pushed consecutively twice (within two seconds),the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETAC-ECU tone alarm will sound twice. 3. If the transmiller "UNLOCK" switch is pushed consecutively twice (within two seconds), the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. 4. Exit the hazard answerback customize mode by observing one of the following steps. 1. Disconnect scan tool MB991502 from the data link connector, or disconnect data link connector terminal (1) form the ground. 2. Turn the ignition switch to position other then LOCK (OFF), or remove the ignition key. 3. Open the driver's side door. NOTE: If any operation is not done for at least three minutes after the ETACS-ECU has entered the customize mode, the hazard answerback customize mode will be canceled automatically 1. Remove the ignition key. 2. Push the LOCK switch while holding the UNLOCK switch pushed for four to ten seconds. 3. If the LOCK switch and UNLOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5485 answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound twice. 4. If the UNLOCK switch and LOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the door are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5486 Keyless Entry: Service and Repair How to Replace the Transmitter Battery HOW TO REPLACE THE TRANSMITTER BATTERY CAUTION: Do not allow water or dust stick to enter the inside of the transmitter when it is open. Also, do not touch the precision electronic device. 1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+) side face-down. Battery required for replacement: Coin type battery CR2032 3. Insert the claw first and assemble the transmitter. 4. Verify that the keyless entry system operates. Keyless Entry System Timer Lock Function Inspection KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION Attempt to unlock the doors by using the transmitter. If the doors are not locked within 30 seconds, carry out troubleshooting. Enabling/Disabling the Answerback Function ENABLING DISABLING THE ANSWERBACK FUNCTION If the keyless entry system locks or unlocks the doors, the dome light flashes or illuminates, the hazard warning light flashes (hazard answer back function) and the horn sounds (horn answer back function). The hazard and horn answer back functions can be enabled or disabled according to the following procedure: Enabling/Disabling the Hazard Answerback Function The hazard answer back function can be enabled or disabled by one of the two following procedure 1. Enter the hazard answerback customize mode by observing one of the following steps. If the ETACS-ECU enters the customize mode, its tone alarm will sound once. 1. Turn the ignition switch to the LOCK (OFF) position. 2. Turn off the hazard warning light switch. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5487 3. Connect scan tool MB991502 to the data link connector terminal (1). 4. Close the driver's side door. 5. Keep the windshield washer switch on for at least ten seconds. Then the ETACS-ECU tone alarm will sound once. 2. If the transmitter LOCK switch is pushed consecutively twice (within two seconds),the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETAC-ECU tone alarm will sound twice. 3. If the transmiller "UNLOCK" switch is pushed consecutively twice (within two seconds), the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. 4. Exit the hazard answerback customize mode by observing one of the following steps. 1. Disconnect scan tool MB991502 from the data link connector, or disconnect data link connector terminal (1) form the ground. 2. Turn the ignition switch to position other then LOCK (OFF), or remove the ignition key. 3. Open the driver's side door. NOTE: If any operation is not done for at least three minutes after the ETACS-ECU has entered the customize mode, the hazard answerback customize mode will be canceled automatically 1. Remove the ignition key. 2. Push the LOCK switch while holding the UNLOCK switch pushed for four to ten seconds. 3. If the LOCK switch and UNLOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound twice. 4. If the UNLOCK switch and LOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the door are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. Enabling/Disabling the Horn Answerback Function 1. Remove the ignition key. 2. Push the UNLOCK switch while holding the LOCK switch pushed for four to ten seconds. 3. If the LOCK switch and UNLOCK switch are released at the same time, the ETACS-ECU tone alarm will sound, indicating that the horn answerback function can be enabled or disabled. Enable the horn answerback function*: The ETACS-ECU tone alarm will sound once. - Disable the horn answerback function: The ETACS-ECU tone alarm will sound twice. - Enable the horn answerback function**: The ETACS-ECU tone alarm will sound three times. NOTE:*: The horn will sound if the doors are locked with the keyless entry system. NOTE:**: The horn will sound if the doors are already locked and the keyless entry system is used. Secret Code Registration Method Each individual secret code is registered inside the transmitter, and so it is necessary to resister these codes with the EEPROM inside the receiver in the following cases. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5488 - When the transmitter or ETACS-ECU is replaced - If more transmitters are to be used - If it appears that a problem is occurring because of faulty registration of a code. A maximum of four different codes can be stored in the EEPROM memory (four different transmitters can be used). When the code for the first transmitter is registered, the previously registered codes for all transmitters are cleared. Therefore, if you are using four transmitters or are adding more transmitters, the codes for all transmitters must be registered at the same time. 1. Check that the doors lock normally when the key is used. 2. Insert the ignition key. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting scan tool MB991502. 3. Connect the scan tool to the data link connector. If the scan tool is not used, ground terminal (1) of the data link connector. NOTE: This will connect terminal (1) of the data link connector to ground, and the system will be in secret code registration standby mode. 4. Press the hazard switch six times within 10 seconds. NOTE: If the switch is depressed six times, all the doors will be locked and then unlocked to enter the registration mode. NOTE: The hazard warning light switch is turned on and off alternately whenever it is pushed. 5. Press the transmitter switch, and then press it two times within 10 seconds of the first press. This will register the code. 6. Once the registration has completed, all the doors will be locked and then unlocked. 7. If you are using two or more transmitters or have added a second transmitter, the same registration procedure should be carried out within one minute after registering the code for the first transmitter. 8. Registration mode will be canceled under the following conditions: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5489 - When the secret code for four transmitters has been registered; - When one minute has been passed after registration mode started; - When scan tool MB991502 is disconnected (the ground connection is broken); - When the key is removed from the key cylinder; 9. After the registration is completed, carry out the following work, and then check that the keyless entry system operates normally. - Remove the ignition key. - Close all of the doors. Removal and Installation DOOR HANDLE AND LATCH Removal And Installation INSTALLATION SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5490 >>A<< DOOR CHECK INSTALLATION Install the door check so that the identification mark faces upwards. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Service and Repair > Page 5491 Special Tools Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Garage Door Opener Transmitter: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair Amplifier: Service and Repair REMOVAL AND INSTALLATION WARNING: Before removing a seat equipped with the side air bag module, refer to SRS Service Precautions. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed Compact Disc Player (CD): Customer Interest Audio System - 'CD ERR' Message Displayed NUMBER: 08-028-03 GROUP: Electrical DATE: September 19, 2003 SUBJECT: Radio CD ERR Message MODELS: 2002 - 2003 (AN) Dakota 2002 - 2003 (DN) Durango 2002 - 2004 (DR) Ram Truck 2004 (HB) Durango 2002 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2002 - 2004 (PL) Neon 2002 - 2004 (PT) Chrysler PT Crusier 2002 - 2004 (RG) Chrysler Voyager (International Markets) 2002 - 2004 (RS) Town & Country/Voyager/Caravan 2002 - 2004 (TJ) Wrangler 2002 - 2004 (WG) Grand Cherokee (International Markets) 2002 - 2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper NOTE: This bulletin applies to vehicles equipped radio sales codes RAZ, RAD, RBK, RBP, RAH, REF, RAQ and RAR. DISCUSSION: Here are some common problems of why a CD ERR may occur: 1. CD's are not always compatible with a CD player. Usually these are homemade CD's (write/re-write), however some low quality CD's may not be compatible. 2. Scratches on a CD. Most of the time a CD will skip when the player sees a scratch but in some cases the scratches are so severe that a CD ERR will occur. 3. Finger prints on the CD. The oil from finger prints may prevent the Optical Pickup from reading the disc. 4. Foreign materials on a CD such as; carpet fibers, liquid spills, candy, etc. may prevent the Optical Pickup from reading a disc. 5. CD's warped from being in extreme heat. If a CD is warped too much then it should not fit into the CD slot, thus preventing insertion. However, some CD's that are not perfectly flat may be inserted with little effort. The CD player may or may not read these CD's. 6. In climate condition where the CD player is exposed to frigid temperatures or high humidity condensation may form on the Optical Pickup. This condition will correct itself once the vehicle's cabin temperature stabilizes. What a dealer should do before removing a CD player for repair. 1. Find out as much information as possible about the failure from the customer. a. Does the CD player work at all or is it intermittent? b. Does the failure occur when using certain CD's? c. Are the CD's homemade or inexpensive CD's? d. Does the failure occur during the first few minutes when the temperature is either frigid or hot and humid? e. Will the customer make his CD's available to you for testing and inspection? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed > Page 5529 2. Inspect the customers CD's. a. Look for scratches, finger prints, foreign materials. . Look for warped CD's. 3. Test the CD player with a known good CD. 4. Test the customer's CD's in a like unit. Do not test in a different type of CD player because CD players vary in performance from manufacturer to manufacturer and model to model. 5. If the condition can be verified and it is the CD player's fault, replace the unit. Caution for customers: 1. Do not use CD's with labels. CD players operate at a high temperature which may cause the label to peel up or come off. This may prevent the CD from ejecting or if label falls into the mechanism it may cause the mechanism to jam. 2. When CD's are not in use, store them in a method to prevent them from getting damaged. 3. Clean the CD's before using them. To clean a CD, use rubbing alcohol and a soft cloth. Wipe the CD from the center to the outboard edge, not a circular motion. 4. Do not try to remove a jammed CD. POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed Compact Disc Player (CD): All Technical Service Bulletins Audio System - 'CD ERR' Message Displayed NUMBER: 08-028-03 GROUP: Electrical DATE: September 19, 2003 SUBJECT: Radio CD ERR Message MODELS: 2002 - 2003 (AN) Dakota 2002 - 2003 (DN) Durango 2002 - 2004 (DR) Ram Truck 2004 (HB) Durango 2002 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2002 - 2004 (PL) Neon 2002 - 2004 (PT) Chrysler PT Crusier 2002 - 2004 (RG) Chrysler Voyager (International Markets) 2002 - 2004 (RS) Town & Country/Voyager/Caravan 2002 - 2004 (TJ) Wrangler 2002 - 2004 (WG) Grand Cherokee (International Markets) 2002 - 2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper NOTE: This bulletin applies to vehicles equipped radio sales codes RAZ, RAD, RBK, RBP, RAH, REF, RAQ and RAR. DISCUSSION: Here are some common problems of why a CD ERR may occur: 1. CD's are not always compatible with a CD player. Usually these are homemade CD's (write/re-write), however some low quality CD's may not be compatible. 2. Scratches on a CD. Most of the time a CD will skip when the player sees a scratch but in some cases the scratches are so severe that a CD ERR will occur. 3. Finger prints on the CD. The oil from finger prints may prevent the Optical Pickup from reading the disc. 4. Foreign materials on a CD such as; carpet fibers, liquid spills, candy, etc. may prevent the Optical Pickup from reading a disc. 5. CD's warped from being in extreme heat. If a CD is warped too much then it should not fit into the CD slot, thus preventing insertion. However, some CD's that are not perfectly flat may be inserted with little effort. The CD player may or may not read these CD's. 6. In climate condition where the CD player is exposed to frigid temperatures or high humidity condensation may form on the Optical Pickup. This condition will correct itself once the vehicle's cabin temperature stabilizes. What a dealer should do before removing a CD player for repair. 1. Find out as much information as possible about the failure from the customer. a. Does the CD player work at all or is it intermittent? b. Does the failure occur when using certain CD's? c. Are the CD's homemade or inexpensive CD's? d. Does the failure occur during the first few minutes when the temperature is either frigid or hot and humid? e. Will the customer make his CD's available to you for testing and inspection? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed > Page 5535 2. Inspect the customers CD's. a. Look for scratches, finger prints, foreign materials. . Look for warped CD's. 3. Test the CD player with a known good CD. 4. Test the customer's CD's in a like unit. Do not test in a different type of CD player because CD players vary in performance from manufacturer to manufacturer and model to model. 5. If the condition can be verified and it is the CD player's fault, replace the unit. Caution for customers: 1. Do not use CD's with labels. CD players operate at a high temperature which may cause the label to peel up or come off. This may prevent the CD from ejecting or if label falls into the mechanism it may cause the mechanism to jam. 2. When CD's are not in use, store them in a method to prevent them from getting damaged. 3. Clean the CD's before using them. To clean a CD, use rubbing alcohol and a soft cloth. Wipe the CD from the center to the outboard edge, not a circular motion. 4. Do not try to remove a jammed CD. POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Radio/Stereo: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Radio/Stereo: Electrical Diagrams Vehicles With Amplifier Audio System Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 Audio System Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 Audio System Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 Audio System Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Audio System Part 5 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Vehicles Without Amplifier Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 Audio System Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 Audio System Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair Speaker: Service and Repair Removal And Installation Center Speaker Tweeter, Door Speaker Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Page 5571 Rear Speaker Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Horn Relay > Component Information > Locations Alarm Horn Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Overall View View G Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information Towing Information: Technician Safety Information STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 5584 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 5585 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 5586 Towing Information: Vehicle Damage Warnings STANDARD PROCEDURE - TOWING RECOMMENDATIONS CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Fig. 9 Tow Vehicles With Approved Equipment A vehicle equipped with SAE approved sling-type towing equipment, a wheel-lift towing device or a vehicle with a flat-bed device can be used to transport all RAM VAN or WAGON vehicles (Fig. 9). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. Safety Precautions NOTE: The following safety precautions must be observed when towing a vehicle. - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Remove exhaust pipe tips that interfere with the tow sling and crossbar - Padding should be placed between the tow sling/crossbar and any painted surfaces - When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or hoses - Do not tow the vehicle by connecting to the front or rear shock absorbers - Do not tow a heavily loaded vehicle. Damage to the vehicle may result. Use a flatbed device to transport a loaded vehicle. Ground Clearance CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain, steep rises in the road or if the vehicle is equipped with air dams, spoilers, and/or ground effect panels. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums. Ramp Angle If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 5587 Towing-Rear End Lifted CAUTION: Do not use steering column lock to secure steering wheel during towing operation. Vehicles can be towed with the front wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph). Fig. 10 Rear-End Lifted Towing 1. Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 10). 2. Position and center the sling under and forward of the rear bumper. 3. Attach safety chains (with pads) at each end of the rear bumper. 4. Turn the ignition switch to the OFF position to unlock the steering wheel. 5. Clamp the steering wheel with the front wheels in the straight ahead position. 6. Shift the transmission to NEUTRAL. Towing-Front End Lifted Provided the transmission is operable, tow only in NEUTRAL at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Technician Safety Information > Page 5588 Fig. 11 Front-End Lifted Towing - Typical If a vehicle cannot be towed from the rear, the front-end raised towing method normally can be used (Fig. 11). 1. Center the sling with the bumper and position it at the frame front crossmember. CAUTION: Use tow chains with J-hooks for connecting to the disabled vehicle's lower suspension arms. Never use T-hooks. 2. Route the J-hooks and tow chains over the steering linkage outboard of the coil spring. 3. Attach the J-hooks to the outer end of the lower suspension arms. 4. Raise the vehicle. 5. Attach the safety chains to the disabled vehicle at the frame rails. Towing When Keys Are Not Available When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used provided all the wheels are lifted off the ground using tow dollies. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Page 5589 Towing Information: Service and Repair WRECKER TOWING RECOMMENDATION FRONT TOWING PICKUP CAUTION: This vehicle cannot be towed by a wrecker using sling- type equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equipment. The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible. REAR TOWING PICKUP CAUTION: This vehicle cannot be towed by a wrecker using sling-type equipment, otherwise the lower may suffer deformation. If this vehicle is towed, use a wheel lift or flat bed equipment. - Do not use the steering column lock to secure the front wheel for towing. - Make sure the transaxle is in Neutral if vehicle will have drive wheels on the ground. - If these limits cannot be met, the front wheels must be placed on a tow dolly. Automatic transmission vehicle may be towed on the front wheels at speeds not to exceed 50 km/h (30 mph) for distances not to exceed 30 km (18 miles). TOWING WHEN KEYS ARE NOT AVAILABLE Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service Precautions > Page 5590 When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front, provided the parking brake is released. If not released, the rear wheels should be placed on a tow dolly. SAFETY PRECAUTIONS The following precautions should be taken when towing the vehicle: 1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER. 2. Any loose or protruding parts or damaged vehicle such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle. 3. Operator should retrain from going under a vehicle if is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands. 4. Never allow passengers to ride in a towed vehicle. 5. state and local rules and regulations must be followed when towing a vehicle. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > System Information > Service and Repair > Removal and Replacement Front Bumper: Removal and Replacement FRONT BUMPER ASSEMBLY REMOVAL AND INSTALLATION Required Special Tool: - MB990784: Ornament Remover Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > System Information > Service and Repair > Removal and Replacement > Page 5597 Front Bumper: Overhaul DISASSEMBLY AND ASSEMBLY DISASSEMBLY SERVICE POINT Required Special Tool: - MB990784: Ornament Remover Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > System Information > Service and Repair > Removal and Replacement > Page 5598 1. Use special tool MB990784 to pull up the center pin in clip. 2. Remove the clip. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair > Removal and Replacement Rear Bumper: Removal and Replacement FRONT BUMPER ASSEMBLY REMOVAL AND INSTALLATION Required Special Tool: - MB990784: Ornament Remover REMOVAL SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair > Removal and Replacement > Page 5603 1. Use special tool MB990784 to pull up the center pin in the clip. 2. Remove the clip. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair > Removal and Replacement > Page 5604 Rear Bumper: Overhaul DISASSEMBLY AND ASSEMBLY DISASSEMBLY SERVICE POINT Required Special Tool: - MB990784: Ornament Remover Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Ventilators Part 1 - Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair > Page 5608 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Diagrams Cowl: Diagrams FRONT DECK Large front upper frame extension outers have been adopted to increase the rigidity of the joints between the front pillars and the fender shield. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Specifications Front Door Handle: Specifications Fastener Tightening Specifications Service Specifications Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Specifications > Page 5618 Front Door Handle: Testing and Inspection DOOR INSIDE HANDLE PLAY CHECK AND ADJUSTMENT 1. Check that the door inside handle play is within the standard value range. Standard value (A): 3.2 mm (0.13 inch) 2. If the door inside handle play is outside the standard value range, remove the door trim. 3. Loosen the inside handle mounting screws, and then move the inside handle back and forth to adjust the play. DOOR OUTSIDE HANDLE PLAY CHECK 1. Check that the door outside handle play is within the standard value range. Standard value (B): 2.4 mm (0.09 inch) 2. If the door outside handle play is not within the standard value range, check the door outside handle or the door latch assembly. Replace the door outside handle or the door latch assembly. If it is necessary. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Specifications > Page 5619 Front Door Handle: Service and Repair Removal And Installation INSTALLATION SERVICE POINT >>A<< DOOR CHECK INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Specifications > Page 5620 Install the door check so that the identification mark faces upwards. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications Fastener Tightening Specifications Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 5624 Front Door Latch: Service and Repair Removal And Installation INSTALLATION SERVICE POINT >>A<< DOOR CHECK INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 5625 Install the door check so that the identification mark faces upwards. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments Front Door Window Glass: Adjustments DOOR WINDOW GLASS ADJUSTMENT Remove the door trim. 1. Remove the waterproof film. 2. Remove the drip line weather-strip. 3. Loosen the bolts and nuts of the following parts. - Delta sash assembly - Power window regulator assembly - Glass carrier plate - Up-stop - Rear lower sash Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments > Page 5632 4. Tighten the power window regulator assembly upper bolts and the glass carrier plate mounting bolts so that the clearances between the weather-strip holder and the window glass as well as between the door panel and the window glass meet the respective standard values. (Sections A - A, B - B, C - C, D - D, E - E.) CAUTION: The right and left adjusting bolts should turned by the same number of threads. 5. Turn the lower adjusting bolts (right and left) of the power window regulator assembly until the clearances between the weather-strip and the window glass meet the respective standard values. (Sections F - F, G - G, H - H.) 6. Press the up-stop against the window glass stop, and then tighten the up-stop nut. 7. Lower the window glass to the extreme position. CAUTION: The adjusting bolts should be turned by the same number of threads. 8. Tighten the adjusting bolts (upper and lower) until the rear lower sash is positioned as shown in the illustration, and then lock the nuts. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments > Page 5633 9. Raise the window glass to the extreme position. 10. Turn the adjusting bolt until the gap between the delta sash assembly and the window glass end meets the shown dimension. 11. Lower the window glass. 12. Lock the adjusting bolt of the delta sash assembly with a nut 13. Tighten the two upper bolts at the delta sash assembly. CAUTION: Ensure that the weather-strip is not wrinkled or out of position. 14. Install the drip line weather-strip to the weather-strip holder. 15. Install the waterproof film. 16. Install the door trim. 17. Check the door window glass alignment according to following procedure. 1. Close the door window glass fully, and close the door until the clearance between the door window glass rear end and the weather-strip reaches 100 mm (3.9 inches). At this time, the distance between the rear end of the belt line molding outer and the quarter panel should be 113.5- 118.5 mm (4.46-4.67 inches). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments > Page 5634 2. The clearance between the glass and the glass catch should be within the range of standard values (a, c, e, g) when the window is fully closed and the door is closed gently. Standard value a. : 2.9 ± 1.0 mm (0.11 ± 0.04 inch) c. : 4.5 ± 1.0 mm (0.18 ± 0.04 inch) e. : 3.4 mm (0.13 inch) g. : 10.7 ± 1.0 mm (0.42 ± 0.04 inch) NOTE: If the clearance is too small the glass catch will move above the glass when the door is closed. If the clearance is too large, wind noise may be generated at high vehicle speed because the glass catch is not hooked onto the glass. 3. The amount of catch of the door catch on the door glass and the weather-strip should be at the standard values (b, d, f) when the window is closed fully and then the door is closed. Standard value b. : 2.7 ± 1.0 mm (0.11 ± 0.04 inch) d. : 2.7 ± 1.0 mm (0.11 ± 0.04 inch) f. : 2.4 ± 1.0 mm (0.09 ± 0.04 inch) 4. The door glass should slide smoothly over its full range of movement when the door is closed. 5. The glass catch and the weather-strip should be parallel with the door glass and the two up-stops should touch simultaneously when the glass is fully closed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Adjustments > Page 5635 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Power Window Motor/Window Regulator Assembly Removal And Installation INSTALLATION SERVICE POINTS >>A<< POWER WINDOW MOTOR/WINDOW REGULATOR ASSEMBLY INSTALLATION 1. Power window motor and window regulator assembly installation procedure CAUTION: Do not operate the power window motor until the glass installation is finished. 1. Connect the power window motor to the body-side harness connector, and then turn on the ignition switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 5639 2. Continue to pull the power window switch until the power window motor stops. NOTE: Power window motor stops automatically and the limit switch incorporated in the power motor will be reset. 3. Turn off the ignition switch, and then remove window motor from the body-side harness connector. 4. Align the power window motor drive shaft and the square hole in the drum by the following procedure, while using the guide and the opening in the motor housing as a reference for the installation position. a. Align the square hole with the drive shaft by sliding the glass bracket (glass mounting section) or by turning the drum using a ratchet wrench [with a socket diameter of 12.7 mm (0.50 inch)). b. Turn the drum to position the glass bracket as shown in the illustration. Support the drum and the guide with your hand while turning the drum, otherwise the wires may pull out of the drum. c. If the wires pull out of the drum, reinsert them by following the drum and regulator wire installation procedure. 5. Align the guide and the opening of the motor housing, and slide the guide into the motor housing while holding the guide and drum. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 5640 CAUTION: Make sure that the metal cover is installed securely and do not move, in order to stop the drum from vibrating. If the drum vibrates, the glass may not slide up and down smoothly, or it may fall down. 6. install the metal cover securely to housing. 2. Drum and regulator wire installation procedure 1. Place the drum, guide and regulator on a work bench as shown in the illustration. a. Place the drum so that the square hole is facing upward. b. Place the guide so that the slits are facing upward. c. Place the regulator so that the glass bracket is facing downward. Position the glass bracket so that glass is in the fully-open position. 2. Pass the springs over the wires, and then install the lowering wire to the guide first, followed by the lifting wire. (The lifting wire should be on top of the lowering wire.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 5641 3. Use some narrow-gauge wire [approximately 0.5 mm (0.02 inch) diameter] to compress the springs, and then tie the narrow-gauge wire a to the slits in the guide. 4. Insert the end of the lowering wire into the wire hole at the bottom of the drum, and then wrap the bottom so that there is no slackness in the wire. 5. Install the lifting wire to the drum as following: a. Insert the end of the lifting wire into the wire hole at the top of the drum. b. Raise the front of the drum until the drum is vertical, and then position the lifting wire in the groove of the drum. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 5642 c. Return the drum to its original position while holding the wires to make sure that they do not pull out. 6. After installing the power window motor assembly to the power window regulator assembly, cut and remove the wires witch are compressing the springs. 3. Operation check CAUTION: Do not operate the power window regulator assembly before installing the window glass, otherwise the limit switch will be set. Window glass safety mechanism does not operate when the window glass is closed fully at first time. 1. Install the window glass to the power window regulator assembly. 2. Close the window glass completely. NOTE: Closing the window glass completely will finish the adjustment of the limit switch. 3. Check that the limit switch operates correctly. >>B<< DOOR WINDOW GLASS INSTALLATION 1. Temporarily secure the door window glass to the door window regulator. 2. After raising the door window glass as far as it will go, fully secure the door window glass to the power window regulator assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Component Information > Adjustments Hood: Adjustments HOOD ADJUSTMENT OF HOOD FIT 1. If the clearance between the hood and the body is uneven, loosen the hood mounting bolts (if the hood was removed) or loosen the hood hinge mounting bolts (if the hood and hood hinges were removed), and then move the hood forward, backward and sideways until the clearance around the hood is uniform. Hood mounting bolt tightening torque: 5.0 ± 1.0 N.m 44 ± 9 in-lb Hood hinge mounting bolt tightening torque: 5.0 ± 1.0 N.m 44 ± 9 in-lb 2. Turn the hood bumpers either left or right to adjust the height of the hood. 3. If the hood is not flush or if latching and unlatching feels heavy, first check the condition of the release cable, and then loosen the hood latch mounting bolts and move the hood latch to adjust it so that it engages the hood striker correctly. Hood latch mounting bolt tightening torque: 12 ± 2 N.m 102 ± 22 in-lb Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Component Information > Application and ID Trunk / Liftgate: Application and ID TRUNK LID ADJUSTMENT OF TRUNK LID FIT 1. If the clearance between the trunk lid and the body is not uniform, loosen the trunk lid mounting bolts and move the trunk lid to adjust so that the clearance around the trunk lid is uniform. Trunk lid mounting bolt tightening torque: 5.0 ± 1.0 N.m 44 ± 9 in-lb 2. Turn the trunk lid bumpers either left or right to adjust the height of the trunk lid. 3. If the step, floating, locking and unlocking of the trunk lid are heavy, check the condition of the release cable, and then loosen the trunk lid striker mounting bolts and move the trunk lid striker to adjust the meshing with the trunk lid latch. Trunk lid striker mounting bolt tightening torque: 8.9 ± 1.9 N.m 79 ± 17 in-lb Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Specifications Adhesives Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Specifications > Page 5653 Body Emblem: Service and Repair REMOVAL AND INSTALLATION Required Special Tool: - MB990528: Stripe Tape Spatula INSTALLATION SERVICE POINT >>A<< MARK INSTALLATION Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Specifications > Page 5654 1. APPLICATION LOCATION Each dimension from the edge to the notch of the mark should be equal to each installation dimension. (i.e. A = A' and C = C') CAUTION: Work in a dust-free workplace with temperature of 20 - 38 degrees C (60 - 100 degrees F). - If workplace temperature is under 20 degrees C (60 degrees F), warm tape and vehicle body (adhesion area) to 20 - 38 degrees C (60 - 100 degrees F). 2. Install the tape by the following procedure. 1. Use 3M(TM) AAD Part number 8906 or equivalent to wipe off oil from stripe tape adhesion area. 2. Remove protective paper from back of stripe tape and adhere entirely to indicated area. CAUTION: Pressing the mark horizontally may lead to a slack, clinching or improper position. - If the mark is pressed improperly, the mark may be easily peeled off. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Specifications > Page 5655 3. Make sure that air bubbles are not trapped in the application surface. When applying the mark, use special tool MB990528 to press the mark from its center to top and bottom gradually. 4. Peel off an application tape (top protection paper) horizontally and carefully from one end. If an air bubble is left in the mark, open a hole by using a needle, and then use special tool MB990528 to expel the air bubble. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Firewall > Component Information > Diagrams Firewall: Diagrams DASH PANEL A deadening sheet (foam rubber sheet) has been placed in between the dash panel and the dash panel reinforcement to create a double-walled structure which improves sound insulation. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications Front Cross-Member: Specifications Crossmember and stay connecting bolt <2.4L Engine> ............................................................................................................... 74 ± 4 Nm (55 ± 3 ft. lbs.) Crossmember mounting bolt .................................................................................................................................................... 108 ± 10 Nm (80 ± 7 ft. lbs.) Crossmember mounting nut ........................................................................................................................................................ 88 ± 10 Nm (65 ± 7 ft. lbs.) Lower arm and crossmember connecting nut ........................................................................................................................... 108 ± 10 Nm (80 ± 7 ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications > Page 5664 Front Cross-Member: Diagrams CROSSMEMBER Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications > Page 5665 Front Cross-Member: Service and Repair CROSSMEMBER REMOVAL AND INSTALLATION CAUTION: ^ * Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. ^ For vehicles with SRS, before removal of steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render the SRS system inoperative, risking serious injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications > Page 5666 Required Special Tools: ^ MB990828: Bushing Remover and Installer ^ MB991045: Bushing Remover and Installer CROSSMEMBER BUSHING REPLACEMENT Crossmember Bushings A and B 1. Apply soapy water to the contact surface of the bushing when press-fitted the bushing. 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard values <2.4L ENGINE> ^ Bushing A: 9.0 ± 1.0 mm (0.35 ± 0.04 in.) ^ Bushing B: 4.0 ± 1.0 mm (0.16 ± 0.04 in.) <3.0L ENGINE> ^ Bushing A, B: 9.0 ± 1.0 mm (0.35 ± 0.04 in.) Crossmember Bushing C 1. Use special tool l\4B990828 to drive out and press-fit the Crossmember bushing C. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications > Page 5667 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard value (A): 4.0 ± 0.5 mm (0.16 ± 0.02 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Service and Repair Front Cross-Member Bushing: Service and Repair CROSSMEMBER BUSHING REPLACEMENT Crossmember Bushings A and B 1. Apply soapy water to the contact surface of the bushing when press-fitted the bushing. 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard values ^ Bushing A: 9.0 ± 1.0 mm (0.36 ± 0.04 in.) ^ Bushing B: 4.0 ± 1.0 mm (0.16 ± 0.04 in.) Crossmember Bushing C 1. Use special tool MB990828 to drive out and press-fit the crossmember bushing C. 2. The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard value (A): 4.0 ± 0.5 mm (0.16 ± 0.02 in.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Key Cylinder Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Keyless Entry: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 Keyless Entry: Electrical Diagrams Central Door Locking System Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 Central Door Locking System Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 Central Door Locking System Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 Central Door Locking System Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 Central Door Locking System Part 5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 Central Door Locking System Part 6 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 Central Door Locking System Part 7 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Central Door Locking System Part 8 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Central Door Locking System Part 8 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 Central Door Locking System Part 10 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 Central Door Locking System Part 11 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 Central Door Locking System Part 12 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 Central Door Locking System Part 13 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Diagrams > Page 5722 Keyless Entry: Description and Operation GENERAL DESCRIPTION OPERATION KEYLESS ENTRY SYSTEM Some models are equipped with a radio-controlled keyless entry system. The main features are: - Antenna and receiver are incorporated in the ETACS-ECU. - ID code can be registered by using the scan tool (MUT- II). - Transmitter is a key holder type, which incorporates lock switch, unlock switch, trunk switch and panic switch. - The locking is answered back by two times' flashing of the dome light, two times' flashing of the turn signal light and one time blowing of the horn. - The unlocking is answered back by lighting of the dome light for 15 seconds and one time flashing of the turn signal light. KEYLESS ENTRY SYSTEM OPERATION Keyless Entry Answerback Function If the RKE transmitter "LOCK" or "UNLOCK" switch is pressed while the ignition key is removed, the doors can be locked or unlocked. If the doors are closed, the hazard warning lights, the interior lights and the horn will operate due to answerback function. Because of the answerback function, the hazard warning lights flash twice, and the horn sounds once, the interior lights flashes twice when the doors are locked. Meanwhile, when the doors are unlocked, the hazard warning lights flash and the interior lights illuminates for 30 seconds. The hazard and the horn answerback functions can be cancelled by using the transmitter. Keyless Entry Room Lamp Answerback Interior lights's answerback operation in response to door lock control by keyless entry system: To allow the driver to confirm the doors have locked by the keyless entry system, the ETACS-ECU causes the interior lights to blink twice when the doors are locked by the RKE system and to illuminate for approximately 30 seconds when the doors are locked. The interior lights' answerback operation in response to a keyless entry system control action is accompanied by flashing of the hazard warning lights. Trunk Lid Opener Function After "TRUNK" switch of the transmitter is pushed "ON" twice within 5 seconds without ignition key in the key hole, ETAGS-ECU makes trunk lid opener actuator open the trunk lid. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery Keyless Entry: Service and Repair How to Replace the Transmitter Battery HOW TO REPLACE THE TRANSMITTER BATTERY CAUTION: Do not allow water or dust stick to enter the inside of the transmitter when it is open. Also, do not touch the precision electronic device. 1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+) side face-down. Battery required for replacement: Coin type battery CR2032 3. Insert the claw first and assemble the transmitter. 4. Verify that the keyless entry system operates. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5725 Keyless Entry: Service and Repair Keyless Entry System Timer Lock Function Inspection KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION Attempt to unlock the doors by using the transmitter. If the doors are not locked within 30 seconds, carry out troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5726 Keyless Entry: Service and Repair Enabling/Disabling the Answerback Function ENABLING DISABLING THE ANSWERBACK FUNCTION If the keyless entry system locks or unlocks the doors, the dome light flashes or illuminates, the hazard warning light flashes (hazard answer back function) and the horn sounds (horn answer back function). The hazard and horn answer back functions can be enabled or disabled according to the following procedure: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5727 Keyless Entry: Service and Repair Enabling/Disabling the Hazard Answerback Function The hazard answer back function can be enabled or disabled by one of the two following procedure 1. Enter the hazard answerback customize mode by observing one of the following steps. If the ETACS-ECU enters the customize mode, its tone alarm will sound once. 1. Turn the ignition switch to the LOCK (OFF) position. 2. Turn off the hazard warning light switch. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting scan tool MB991502. 3. Connect scan tool MB991502 to the data link connector terminal (1). 4. Close the driver's side door. 5. Keep the windshield washer switch on for at least ten seconds. Then the ETACS-ECU tone alarm will sound once. 2. If the transmitter LOCK switch is pushed consecutively twice (within two seconds),the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETAC-ECU tone alarm will sound twice. 3. If the transmiller "UNLOCK" switch is pushed consecutively twice (within two seconds), the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. 4. Exit the hazard answerback customize mode by observing one of the following steps. 1. Disconnect scan tool MB991502 from the data link connector, or disconnect data link connector terminal (1) form the ground. 2. Turn the ignition switch to position other then LOCK (OFF), or remove the ignition key. 3. Open the driver's side door. NOTE: If any operation is not done for at least three minutes after the ETACS-ECU has entered the customize mode, the hazard answerback customize mode will be canceled automatically 1. Remove the ignition key. 2. Push the LOCK switch while holding the UNLOCK switch pushed for four to ten seconds. 3. If the LOCK switch and UNLOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5728 answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound twice. 4. If the UNLOCK switch and LOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the door are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5729 Keyless Entry: Service and Repair How to Replace the Transmitter Battery HOW TO REPLACE THE TRANSMITTER BATTERY CAUTION: Do not allow water or dust stick to enter the inside of the transmitter when it is open. Also, do not touch the precision electronic device. 1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+) side face-down. Battery required for replacement: Coin type battery CR2032 3. Insert the claw first and assemble the transmitter. 4. Verify that the keyless entry system operates. Keyless Entry System Timer Lock Function Inspection KEYLESS ENTRY SYSTEM TIMER LOCK FUNCTION INSPECTION Attempt to unlock the doors by using the transmitter. If the doors are not locked within 30 seconds, carry out troubleshooting. Enabling/Disabling the Answerback Function ENABLING DISABLING THE ANSWERBACK FUNCTION If the keyless entry system locks or unlocks the doors, the dome light flashes or illuminates, the hazard warning light flashes (hazard answer back function) and the horn sounds (horn answer back function). The hazard and horn answer back functions can be enabled or disabled according to the following procedure: Enabling/Disabling the Hazard Answerback Function The hazard answer back function can be enabled or disabled by one of the two following procedure 1. Enter the hazard answerback customize mode by observing one of the following steps. If the ETACS-ECU enters the customize mode, its tone alarm will sound once. 1. Turn the ignition switch to the LOCK (OFF) position. 2. Turn off the hazard warning light switch. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting scan tool MB991502. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5730 3. Connect scan tool MB991502 to the data link connector terminal (1). 4. Close the driver's side door. 5. Keep the windshield washer switch on for at least ten seconds. Then the ETACS-ECU tone alarm will sound once. 2. If the transmitter LOCK switch is pushed consecutively twice (within two seconds),the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETAC-ECU tone alarm will sound twice. 3. If the transmiller "UNLOCK" switch is pushed consecutively twice (within two seconds), the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. 4. Exit the hazard answerback customize mode by observing one of the following steps. 1. Disconnect scan tool MB991502 from the data link connector, or disconnect data link connector terminal (1) form the ground. 2. Turn the ignition switch to position other then LOCK (OFF), or remove the ignition key. 3. Open the driver's side door. NOTE: If any operation is not done for at least three minutes after the ETACS-ECU has entered the customize mode, the hazard answerback customize mode will be canceled automatically 1. Remove the ignition key. 2. Push the LOCK switch while holding the UNLOCK switch pushed for four to ten seconds. 3. If the LOCK switch and UNLOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the doors are locked. Enable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are locked: The ETACS-ECU tone alarm will sound twice. 4. If the UNLOCK switch and LOCK switch are released in that order, the ETACS-ECU tone alarm will sound, indicating that the hazard answerback function can be enabled or disabled when the door are unlocked. Enable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound once. - Disable the hazard answerback function when the doors are unlocked: The ETACS-ECU tone alarm will sound twice. Enabling/Disabling the Horn Answerback Function 1. Remove the ignition key. 2. Push the UNLOCK switch while holding the LOCK switch pushed for four to ten seconds. 3. If the LOCK switch and UNLOCK switch are released at the same time, the ETACS-ECU tone alarm will sound, indicating that the horn answerback function can be enabled or disabled. Enable the horn answerback function*: The ETACS-ECU tone alarm will sound once. - Disable the horn answerback function: The ETACS-ECU tone alarm will sound twice. - Enable the horn answerback function**: The ETACS-ECU tone alarm will sound three times. NOTE:*: The horn will sound if the doors are locked with the keyless entry system. NOTE:**: The horn will sound if the doors are already locked and the keyless entry system is used. Secret Code Registration Method Each individual secret code is registered inside the transmitter, and so it is necessary to resister these codes with the EEPROM inside the receiver in the following cases. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5731 - When the transmitter or ETACS-ECU is replaced - If more transmitters are to be used - If it appears that a problem is occurring because of faulty registration of a code. A maximum of four different codes can be stored in the EEPROM memory (four different transmitters can be used). When the code for the first transmitter is registered, the previously registered codes for all transmitters are cleared. Therefore, if you are using four transmitters or are adding more transmitters, the codes for all transmitters must be registered at the same time. 1. Check that the doors lock normally when the key is used. 2. Insert the ignition key. CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the LOCK (OFF) position before connecting or disconnecting scan tool MB991502. 3. Connect the scan tool to the data link connector. If the scan tool is not used, ground terminal (1) of the data link connector. NOTE: This will connect terminal (1) of the data link connector to ground, and the system will be in secret code registration standby mode. 4. Press the hazard switch six times within 10 seconds. NOTE: If the switch is depressed six times, all the doors will be locked and then unlocked to enter the registration mode. NOTE: The hazard warning light switch is turned on and off alternately whenever it is pushed. 5. Press the transmitter switch, and then press it two times within 10 seconds of the first press. This will register the code. 6. Once the registration has completed, all the doors will be locked and then unlocked. 7. If you are using two or more transmitters or have added a second transmitter, the same registration procedure should be carried out within one minute after registering the code for the first transmitter. 8. Registration mode will be canceled under the following conditions: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5732 - When the secret code for four transmitters has been registered; - When one minute has been passed after registration mode started; - When scan tool MB991502 is disconnected (the ground connection is broken); - When the key is removed from the key cylinder; 9. After the registration is completed, carry out the following work, and then check that the keyless entry system operates normally. - Remove the ignition key. - Close all of the doors. Removal and Installation DOOR HANDLE AND LATCH Removal And Installation INSTALLATION SERVICE POINT Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > How to Replace the Transmitter Battery > Page 5733 >>A<< DOOR CHECK INSTALLATION Install the door check so that the identification mark faces upwards. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Service and Repair > Page 5734 Special Tools Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Key Cylinder Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair Power Door Lock Actuator: Service and Repair Door Lock Actuator Check Door Lock Actuator Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Remote Controlled Mirror Switch Continuity Check Power Mirror Switch: Testing and Inspection Remote Controlled Mirror Switch Continuity Check Remote Controlled Mirror Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Remote Controlled Mirror Switch Continuity Check > Page 5750 Power Mirror Switch: Testing and Inspection Remote Controlled Mirror Switch Illumination Check Remote Controlled Mirror Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Locations > Page 5755 Paint: Application and ID BODY COLOR CHARTS Check the vehicle's body color code and then use this body color chart to determine the refinishing paint supplier from which the color can be purchased. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Sunroof / Moonroof Motor: Locations Overall View View K Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Locations Sunroof / Moonroof Drain: Locations PIPING DIAGRAM There are hoses routed through closed cross-section structures in some areas of the body; before cutting a panel in any of these areas, be sure to remove the hoses. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and Inspection Power Seat Motor: Testing and Inspection Inspect the operation of each motor according to the following procedures. 1. Disconnect the connector for each motor. 2. Check that when the battery is directly connected to the motor terminal, the motor turns smoothly and each adjusting mechanism operates as stated below for each motor. 1. Connect the battery power source to the terminal 3 and ground the terminal 4 for the front/rear height down side and connect the battery power source to the terminal 4 and ground the terminal 3 for the front/rear height up side. 2. Connect the battery power source to the terminal 1 and ground the terminal 2 for the slide backward side and connect the battery power source to the terminal 2 and ground the terminal 1 for the slide forward side. 3. If there is an abnormality, replace the power seat adjuster assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-038-02 > Sep > 02 > Interior - High Seat Sliding Effort Seat Track: Customer Interest Interior - High Seat Sliding Effort NUMBER: 23-038-02 GROUP: Body DATE: Sep. 2, 2002 SUBJECT: Seat Slide Effort NOTE: THIS INFORMATION APPLIES TO MODELS WITH MANUAL SEATS. OVERVIEW: This bulletin involves adjusting the seat tracks to reduce slide effort. MODELS: 2001 - 2003 (ST) Sebring/Stratus Coupe SYMPTOM/CONDITION: Poorly adjusted or installed front seats can make it difficult for the seat locks to engage simultaneously (synchronize) or can cause increased effort to slide the seat fore and aft. Parallelism and/or pitch of the seat track rails can affect this condition. DIAGNOSIS: If the seat slide effort is high or feels ratchety during adjustment, perform the Repair Procedure. REPAIR PROCEDURE: 1. Remove the plastic covers from each of the anchoring corners (1 front-2 rear). Gain access by sliding the seat fore or aft. 2. Loosen both nuts (front) and remove both bolts (rear). 3. Move the seatback to the most upright position. Maintain this position until the adjustment procedure is complete. 4. Slide the seat to the most rearward position. Make sure that both tracks are locked in place and the fore/aft release handle in the front part of the seat, is down (locked position). NOTE: MAKE SURE THE RIGHT AND LEFT TRACKS ARE LOCKED AT EQUAL POSITIONS, IF THEY ARE NOT THE SEAT WILL NOT OPERATE SMOOTHLY. 5. Tighten the front outboard anchor bracket nut first. Torque the outboard nut to 30 +/-5 N.m (22 +/- 4 Ft Lbs). Next tighten the front inboard anchor bracket nut. Torque the inboard nut to the same value. 6. Slide the seat to the most forward position. Make sure both tracks are again locked in place, and that the fore/aft release handle is down (locked position). 7. The holes in the floor pan should be visible through the rear anchoring brackets. Both rear bolts can now be installed and torqued 44 +/- 10 N.m (33 +/- 7 Ft Lbs), in any order. 8. If the seat does not operate smoothly and easily, the outboard rear anchor bracket bolt should be loosened and the anchor bracket moved inboard approximately 2 mm and the bolt retightened. If seat lock synchronization is not symmetrical (even side to side), the inboard rear anchor bracket may also be adjusted. 9. If the seat slide effort becomes too high after step 8, the rear anchor brackets may be adjusted back slightly outboard. Start by adjusting only one rear anchor. Recheck the performance after each adjustment. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 23-038-02 > Sep > 02 > Interior - High Seat Sliding Effort > Page 5779 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-038-02 > Sep > 02 > Interior - High Seat Sliding Effort Seat Track: All Technical Service Bulletins Interior - High Seat Sliding Effort NUMBER: 23-038-02 GROUP: Body DATE: Sep. 2, 2002 SUBJECT: Seat Slide Effort NOTE: THIS INFORMATION APPLIES TO MODELS WITH MANUAL SEATS. OVERVIEW: This bulletin involves adjusting the seat tracks to reduce slide effort. MODELS: 2001 - 2003 (ST) Sebring/Stratus Coupe SYMPTOM/CONDITION: Poorly adjusted or installed front seats can make it difficult for the seat locks to engage simultaneously (synchronize) or can cause increased effort to slide the seat fore and aft. Parallelism and/or pitch of the seat track rails can affect this condition. DIAGNOSIS: If the seat slide effort is high or feels ratchety during adjustment, perform the Repair Procedure. REPAIR PROCEDURE: 1. Remove the plastic covers from each of the anchoring corners (1 front-2 rear). Gain access by sliding the seat fore or aft. 2. Loosen both nuts (front) and remove both bolts (rear). 3. Move the seatback to the most upright position. Maintain this position until the adjustment procedure is complete. 4. Slide the seat to the most rearward position. Make sure that both tracks are locked in place and the fore/aft release handle in the front part of the seat, is down (locked position). NOTE: MAKE SURE THE RIGHT AND LEFT TRACKS ARE LOCKED AT EQUAL POSITIONS, IF THEY ARE NOT THE SEAT WILL NOT OPERATE SMOOTHLY. 5. Tighten the front outboard anchor bracket nut first. Torque the outboard nut to 30 +/-5 N.m (22 +/- 4 Ft Lbs). Next tighten the front inboard anchor bracket nut. Torque the inboard nut to the same value. 6. Slide the seat to the most forward position. Make sure both tracks are again locked in place, and that the fore/aft release handle is down (locked position). 7. The holes in the floor pan should be visible through the rear anchoring brackets. Both rear bolts can now be installed and torqued 44 +/- 10 N.m (33 +/- 7 Ft Lbs), in any order. 8. If the seat does not operate smoothly and easily, the outboard rear anchor bracket bolt should be loosened and the anchor bracket moved inboard approximately 2 mm and the bolt retightened. If seat lock synchronization is not symmetrical (even side to side), the inboard rear anchor bracket may also be adjusted. 9. If the seat slide effort becomes too high after step 8, the rear anchor brackets may be adjusted back slightly outboard. Start by adjusting only one rear anchor. Recheck the performance after each adjustment. POLICY: Reimbursable within the provisions of the warranty. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 23-038-02 > Sep > 02 > Interior - High Seat Sliding Effort > Page 5785 TIME ALLOWANCE: FAILURE CODE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Testing and Inspection Door Lock Key Cylinder Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Remote Controlled Mirror Switch Continuity Check Power Mirror Switch: Testing and Inspection Remote Controlled Mirror Switch Continuity Check Remote Controlled Mirror Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Remote Controlled Mirror Switch Continuity Check > Page 5797 Power Mirror Switch: Testing and Inspection Remote Controlled Mirror Switch Illumination Check Remote Controlled Mirror Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection Power Seat Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Silence Application Locations Sound Proofing / Insulation: Locations Silence Application Locations SILENCER APPLICATION LOCATIONS Silencers (petroleum-asphalt sheets) have been attached to the dash panel and the top of the floor in order to reduce vibration and to insulate against the heat from exhaust gases. In addition, RSS sheets have been placed on top of the silencers on the floor panel to further improve noise suppression. If the silencers or RSS sheets become broken during welded panel replacement or repair, cut a replacement to the shape shown in the illustration and attach it. NOTE: RSS sheet (thermosetting plastic sheet) This sheet is made from denatured resin with asphalt and rubber as its main components, and with a filler material also added. It is molded into sheet form to a constant thickness of 2.0 mm (0.08 in). It has the same excellent vibratory noise suppression characteristics as steel plate-type sandwiched sheets. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Silence Application Locations > Page 5805 Sound Proofing / Insulation: Locations Foaming Agent Usage Locations FOAMING AGENT USAGE LOCATIONS The rear pillars, quarter panels, inner and the lower sections of the center pillars have been filled with foaming agent in order to reduce sound permeation through the frame and to improve quietness. Points to note when working with panels in foaming agent usage locations: The foaming agent may ignite if it is heated, so the following points must be observed without fail. 1. Do not use a gas burner or other similar equipment to heat the areas where foaming agent has been used. 2. When cutting the areas where foaming agent has been used, use equipment (such as a pneumatic saw) which does not produce heat to make the cuts. 3. If any foaming agent is remaining at the cutting locations (on the body side), clean off all foaming agent from around the area before carrying out welding. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Silence Application Locations > Page 5806 Sound Proofing / Insulation: Locations Stiffener and Damping Sheet Application Locations STIFFENER AND DAMPING SHEET APPLICATION LOCATIONS Stiffener has been applied to the inside of the quarter outer panel, lower and damping sheet has been applied to the quarter panel, inner, lower in order to increase surface rigidity and reduce vibration. NOTE: Stiffener is a sheet material made mainly from epoxy resin mixed with glass fibers and filler which becomes stiff when it is heated. It is used for the purpose of improving the rigidity of outer panels. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 5807 Sound Proofing / Insulation: Service and Repair ATTACHMENT OF SILENCERS Silencers (petroleum-asphalt sheets) are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat. If these silencers are peeled.off in the course of replacement or repair of a welded panel, cut and attach replacement material (in the' shape shown in the figure). 1. Heat the "Silencer layer" (petroleum-asphalt sheet) with a blow drier to soften it. 2. Align the silencer layer in the position where it is to be installed, and then press it down with a roller or a block of wood so that it adheres well. NOTE: An infrared lamp can also be used to heat both the silencer layer and the body panels (be sure to wear gloves). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair REAR SPOILER REMOVAL AND INSTALLATION Required Special Tool: - MB990784: Ornament Remover Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Diagrams Cowl: Diagrams FRONT DECK Large front upper frame extension outers have been adopted to increase the rigidity of the joints between the front pillars and the fender shield. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Overall View View E Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Cruise Control > Vacuum Pump, Cruise Control > Component Information > Locations Vacuum Pump: Locations View A Overall View Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Cruise Control > Vacuum Pump, Cruise Control > Component Information > Locations > Page 5827 View A Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 Audible Warning Device: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5852 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5853 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5854 Audible Warning Device: Electrical Diagrams Light Monitor Tone Alarm Lighting Monitor Tone Alarm Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5855 Lighting Monitor Tone Alarm Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Key Reminder Tone Alarm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Key Reminder Tone Alarm Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 Key Reminder Tone Alarm Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Door Ajar Warning Tone Alarm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Door Ajar Warning Tone Alarm Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 Door Ajar Warning Tone Alarm Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Door Ajar Warning Tone Alarm Part 3 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Low Fuel Level Tone Alarm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 Low Fuel Level Tone Alarm Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Low Fuel Level Tone Alarm Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Low Washer Fluid Level Tone Alarm Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Low Washer Fluid Level Tone Alarm Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 Low Washer Fluid Level Tone Alarm Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 5865 Audible Warning Device: Description and Operation CHIME WARNING/REMINDER SYSTEM DESCRIPTION The chime warning/reminder system is controlled by the tone alarm function of the Simplified Wiring System (SWS). The tone alarm is integral to the ETACS-ECU. TONE ALARM FUNCTION OPERATION Ignition Key Reminder Tone Alarm Function When the driver's door is opened (driver's door switch ON) without removing the ignition key [ignition switch to "LOCK" (OFF) position], the tone alarm will sound intermittently to remind the driver that the ignition key has not been removed. Light Reminder Tone Alarm Function When the driver's door is opened (driver's door switch ON) with lighting switch (taillight switch or headlight switch) in the ON position and ignition switch in the "LOCK" (OFF) or "ACC" position, the tone alarm will sound continuously to remind the driver that the lights (taillights or headlights) are ON. This function does not work if the taillights or headlights are switched off through the headlight automatic shutdown function. In addition, the ignition key reminder tone alarm function has a priority over this function. Door Ajar Tone Alarm Function If any of the doors are open, with ignition switch "ON" and with vehicle running at the speed of 8 km/h (5 mph) or more, ETACS-ECU makes a buzzer sound. Low Washer Fluid Level Tone Alarm If 10 seconds have passed after ignition switch has been turned "ON," and then, washer fluid level switch remains at the position "ON" (alarms for washer fluid level getting low) for two seconds or more, ETACS-ECU makes buzzer sound. Buzzer sounds just once after setting ignition switch to the position "ON." Seat Belt Tone Alarm Function When the ignition switch is turned to "ON" position without fastening the seat belts (seat belt switch OFF), the tone alarm will sound for approximately six seconds to warn the driver to fasten the seat belts. When the seat belts are fastened, the tone alarm will stop sounding. Low Fuel Level Tone Alarm Function If seven seconds have passed after ignition switch has been set to the position "ON," and then, low fuel level signal (low fuel level alarm light) from ECM or PCM, is turned "ON," ETACS-ECU makes buzzer sound. Buzzer sounds just once after setting ignition switch to the position "ON." Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 5866 Audible Warning Device: Testing and Inspection CHIME WARNING/REMINDER SYSTEM DIAGNOSIS The chime warning/reminder system are controlled by the tone alarm function of the Simplified Wiring System (SWS). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Brake Warning Indicator: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Brake Warning Indicator: Electrical Diagrams Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection Cigarette Lighter: Testing and Inspection CIGARETTE LIGHTER CHECK - Take out the plug, and check for a worn edge on the element spot connection, and for shreds of tobacco or other material on the element. - Using an ohmmeter, check that the element resistance value is 1.7 ohm. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Page 5897 Cigarette Lighter, Accessory Socket - Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Compass: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 Compass: Electrical Diagrams Compass And Temperature Display Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 Compass And Temperature Display Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Dimmer Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Page 5954 Dimmer Switch: Testing and Inspection RHEOSTAT CHECK 1. Connect the battery and the test bulb (40W) as shown in the illumination. 2. Operate the rheostat, and if brightness changes smoothly without switching off, rheostat function is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Page 5955 Rheostat - Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation DOOR AJAR WARNING LIGHT If any of the doors or the trunk lid are open, ETACS-ECU illuminates door ajar warning light. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Fuel Gauge: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 Fuel Gauge Sender: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Check FUEL GAUGE UNIT CHECK Remove the fuel pump module and the remove the fuel gauge unit. (Refer to Fuel Tank.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 6011 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Resistance FUEL GAUGE UNIT RESISTANCE 1. Check that resistance value between the fuel gauge terminal and ground terminal is at the standard value when the fuel gauge unit float is between point Standard value: Point F: 3-5 ohms - Point E: 110 - 112 ohms 2. Check that resistance value changes smoothly when the float moves slowly between point 3. If no problems are found in steps above, go to Fuel gauge unit float height check. If any problem is found, replace the fuel gauge unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 6012 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Float Height FUEL GAUGE UNIT FLOAT HEIGHT 1. Move the float and measure height A at point Standard value: A: 180.3 mm (7.10 inches) - B: 18.8 mm (0.14 inch) 2. Adjust the float arm to the standard value, then go to Thermistor check. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Key Reminder Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 Key Reminder Switch: Electrical Diagrams Forgotten Key Prevention Function Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Forgotten Key Prevention Function Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Forgotten Key Prevention Function Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Forgotten Key Prevention Function Part 4 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Page 6046 Key Reminder Switch: Testing and Inspection Disconnect key reminder switch connector without removing the ignition switch and steering lock cylinder. Key reminder switch check Check for continuity between terminal 4 and terminal 6. Ignition key ring antenna check Check for continuity between terminal 3 and terminal 7. Standard value: Should be less than 2 ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Low Fuel Lamp/Indicator: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Low Fuel Lamp/Indicator: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 Low Fuel Lamp/Indicator: Electrical Diagrams Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation TROUBLE CODE DIAGNOSIS Among the on-board diagnostic items, a Malfunction Indicator Lamp (SERVICE ENGINE SOON or Check Engine Lamp) illuminates to notify the driver of an emission control malfunction. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Application and ID Oil Change Reminder Lamp: Application and ID This vehicle does not have an Oil Change Reminder Light. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure switch .............................................................................................................................. .......................................... 19 ± 3 Nm (14 ± 2ft. lbs.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 Oil Pressure Warning Lamp/Indicator: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Oil Pressure Warning Lamp/Indicator: Electrical Diagrams Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 Brake Warning Light, Oil Pressure Warning Light, Low Fuel Warning Light Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions Outside Temperature Display: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Outside Temperature Display: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Outside Temperature Display: Electrical Diagrams Compass And Temperature Display Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 Compass And Temperature Display Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Reminder Buzzer: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 Seat Belt Reminder Buzzer: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 Seat Belt Reminder Buzzer: Electrical Diagrams Seat Belt Tone Alarm Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Seat Belt Tone Alarm Part 2 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Reminder Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 Seat Belt Reminder Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Page 6189 Seat Belt Reminder Lamp: Description and Operation SEAT BELT WARNING LIGHT If the driver turns the ignition switch to the "ON" position without wearing the seat belt, the seat belt warning light illuminates to alert the driver to wear the seat belt. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 Dimmer Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 6216 Dimmer Switch: Testing and Inspection RHEOSTAT CHECK 1. Connect the battery and the test bulb (40W) as shown in the illumination. 2. Operate the rheostat, and if brightness changes smoothly without switching off, rheostat function is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 6217 Rheostat - Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Fuel Gauge Sender: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Check FUEL GAUGE UNIT CHECK Remove the fuel pump module and the remove the fuel gauge unit. (Refer to Fuel Tank.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 6245 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Resistance FUEL GAUGE UNIT RESISTANCE 1. Check that resistance value between the fuel gauge terminal and ground terminal is at the standard value when the fuel gauge unit float is between point Standard value: Point F: 3-5 ohms - Point E: 110 - 112 ohms 2. Check that resistance value changes smoothly when the float moves slowly between point 3. If no problems are found in steps above, go to Fuel gauge unit float height check. If any problem is found, replace the fuel gauge unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Fuel Gauge Unit Check > Page 6246 Fuel Gauge Sender: Testing and Inspection Fuel Gauge Unit Float Height FUEL GAUGE UNIT FLOAT HEIGHT 1. Move the float and measure height A at point Standard value: A: 180.3 mm (7.10 inches) - B: 18.8 mm (0.14 inch) 2. Adjust the float arm to the standard value, then go to Thermistor check. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 Key Reminder Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6272 Key Reminder Switch: Electrical Diagrams Forgotten Key Prevention Function Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6273 Forgotten Key Prevention Function Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6274 Forgotten Key Prevention Function Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6275 Forgotten Key Prevention Function Part 4 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Page 6276 Key Reminder Switch: Testing and Inspection Disconnect key reminder switch connector without removing the ignition switch and steering lock cylinder. Key reminder switch check Check for continuity between terminal 4 and terminal 6. Ignition key ring antenna check Check for continuity between terminal 3 and terminal 7. Standard value: Should be less than 2 ohms Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions Speedometer Head: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6281 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6285 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 Speedometer Head: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6289 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Diagram Information and Instructions > Page 6301 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Diagrams > Page 6302 Speedometer Head: Testing and Inspection SPEEDOMETER CHECK Adjust the pressure of tires to the specified level (Refer to On-vehicle Service). CAUTION: Do not operate the clutch suddenly. Do not increase/ decrease speed rapidly while testing. 1. Set the vehicle on to a speedometer tester and use wheel chocks to hold the rear wheels. 2. To prevent the front wheel from moving from side to side, attach tension bars to the tie-down hook, and secure both ends to anchor plates. 3. To prevent the vehicle from moving, attach a chain or wire to the rear retraction hook, and make sure the end of the chain or wire is secured. 4. Check if the speedometer indicator range is within the standard values. 5. If not to the standard value, inspect for proper tire size. If not correct, replace the tires with original size tires and retest. If correct, replace the Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection TACHOMETER CHECK 1. Attach an external high quality tachometer to the engine speed detection connector on the harness side (such as with a paper clip). NOTE: For tachometer check, use an external high quality inductive tachometer. 2. Compare the readings of the vehicle tachometer and the external tachometer at every engine speed, and check if the variations are within the standard values. Standard values: 700 r/min: ± 100 r/min - 3,000 r/min: ± 150 r/min - 5,000 r/min: ± 250 r/min - 6,000 r/min: ± 300 r/min Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Testing and Inspection Temperature Sensor (Gauge): Testing and Inspection 1. Drain the engine coolant. (Refer to Maintenance Service- Engine Coolant.) 2. Remove the engine coolant temperature gauge unit. 3. Immerse the unit in water of 70 °C (158 °F) to measure the resistance. Standard value: 104 ± 13.5 ohms Reference Value 4. If within the standard value, the sensor is OK. Reinstall it, then check the engine coolant temperature gauge. If not within the standard value, replace it. 5. After checking, apply the MOPAR(R) Part No.4318034 or equivalent around the threads of the engine coolant temperature gauge unit. 6. Add engine coolant. (Refer to Maintenance Service Engine Coolant.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Backup Lamp Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 Brake Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Brake Light Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 6386 Brake Light Switch: Testing and Inspection STOPLIGHT SWITCH CHECK 1. Connect an ohmmeter between the stoplight switch connector terminals. 2. There should be no continuity between the terminals when the plunger is pushed in as shown. There should be continuity when it is released. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions Ash Tray Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Ash Tray Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions Glove Box Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 Glove Box Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation Fig.1 Daytime Running Lamp Module Location DAYTIME RUNNING LAMP (CANADA ONLY) JR vehicles built for use in Canada are equipped with a Daytime Running Lamp (DRL) system. The DRL system operates the high beam filaments at a lower intensity when the engine is operating and the exterior lamp switch is in either the OFF or parking lamp ON position and the parking brake is not applied. The DRL system is controlled by the Daytime Running Lamp Module located on the back of the junction block, behind the instrument panel. The DRL module overrides the headlamp switch when the headlamps are turned OFF The headlamps operate normally when the headlamps are turned ON. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. The DRL system is controlled by the Daytime Running Lamp Module located on the back of the junction block, behind the instrument panel. The DRL module overrides the headlamp switch when the headlamps are turned OFF. The headlamps operate normally when the headlamps are turned ON. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 Dimmer Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Page 6466 Dimmer Switch: Testing and Inspection RHEOSTAT CHECK 1. Connect the battery and the test bulb (40W) as shown in the illumination. 2. Operate the rheostat, and if brightness changes smoothly without switching off, rheostat function is normal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Page 6467 Rheostat - Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Dome Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Dome Lamp: Electrical Diagrams Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 6 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 6499 Dome Lamp: Description and Operation INTERIOR LIGHT The ETACS-ECU controls the interior lights (dome light and rear personal lights and foot lights and trunk light) operation as follows: NOTE: Interior lights and rear personal light are controlled only when switch position is set to the position "Door Controlled Operation" Interior Light Dimming Function When a door is opened from outside or inside [with the ignition switch turned to "LOCK" (OFF)]:When a door is opened, the ETACS-ECU causes the interior lights to be illuminated at 100% intensity. When the door is closed, it dims the interior lights to 60% intensity and approximately 30 seconds later, turns out the light completely. During this period (timer controlled period), the interior lights goes out if the ignition switch is turned "ON" or the doors are locked. When a door is opened or closed with the ignition switch in the "6N" position: The interior lights illuminates at 100% intensity when a door is opened and turned out when it is closed. When no door is opened and the ignition key is removed: The interior lights is illuminated at 100% intensity and turned off approximately 30 seconds later. During that time (timer-controlled period), the interior lights goes out if the ignition key is inserted and turned to "ON" or the door locking system is activated. Keyless Entry Room Lamp Answerback Interior lights's answerback operation in response to door lock control by keyless entry system: To allow the driver to confirm the doors have locked by the keyless entry system, the ETACS-ECU causes the interior lights to blink twice when the doors are locked by the RKE system and to illuminate for approximately 30 seconds when the doors are locked. The interior lights' answerback operation in response to a keyless entry system control action is accompanied by flashing of the hazard warning lights. Interior Light Automatic Shut-off Function This function prevents the battery from being discharged when the door is open or the interior lights (dome light and rear personal lights and foot lights and truck light) remains on with the ignition switch at the "LOCK" (OFF) position. The ETACS-ECU turns on its "keep" relay to switch off the battery power supply to the interior lights when the interior light loaded signal, driver's or passenger's door switches or, trunk lid latch switch remain on for approximately 30 minutes with the ignition switch ACC signal is OFF. Then the interior lights will be switched off. If the ignition switch is turned on again, the ETACS-ECU turns on its "keep" relay to illuminate the interior lights. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 6500 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 6505 Fog Light Relay Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation Fog/Driving Lamp Switch: Description and Operation FOG LIGHT The fog light switch becomes active only when the headlights are at the low-beam mode. Therefore, if the headlights are turned off, the fog lights will also be switched off. When the headlights are turned on during the next key cycle, the fog lights will be off regardless of the fog light switch position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Page 6509 Fog Light Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Hazard Warning Light Switch Continuity Check Hazard Warning Light Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Hazard Warning Light Switch Continuity Check > Page 6515 Hazard Warning Switch: Testing and Inspection Hazard Warning Light Switch Diagnosis The hazard warning lights are controlled by the Simplified Wiring System (SWS). For troubleshooting, refer to, SWS Diagnosis. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 6516 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > High Beam Headlamp Bulb Headlamp Bulb: Service and Repair High Beam Headlamp Bulb REPLACEMENT OF HEADLIGHT BULB 1. Disconnect the connector. 2. Remove the sealing cover. CAUTION: Do not touch the surface of the bulb with hands or dirty gloves as the bulb may pop after a short time. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. 3. Remove the headlight bulb 4. Install the sealing cover securely after the bulb replacement, or the lens will be out of focus, or water will get inside the light unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > High Beam Headlamp Bulb > Page 6522 Headlamp Bulb: Service and Repair Low Beam Headlamp Bulb REPLACEMENT OF HEADLIGHT BULB 1. Disconnect the connector. 2. Remove the sealing cover. CAUTION: Do not touch the surface of the bulb with hands or dirty gloves as the bulb may pop after a short time. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. 3. Remove the headlight bulb 4. Install the sealing cover securely after the bulb replacement, or the lens will be out of focus, or water will get inside the light unit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6527 Horn Relay, Theft-Alarm Horn Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Description and Operation Key Cylinder Lamp: Description and Operation IGNITION KEY HOLE ILLUMINATION LIGHT When the ignition switch is turned to the "LOCK" (OFF) or "ACC" position with the driver's door opened, the ignition key hole illumination light is illuminated. If the door is closed in that state, the light goes out after 30 seconds or it illuminates for 30 seconds after the ignition key is removed. In either case the light does out when the ignition switch is turned to the "ON" position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 License Plate Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 License Plate Lamp: Electrical Diagrams Taillight, Parking Light, Side Marker Light And License Plate Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Taillight, Parking Light, Side Marker Light And License Plate Light Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Taillight, Parking Light, Side Marker Light And License Plate Light Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Taillight, Parking Light, Side Marker Light And License Plate Light Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Taillight, Parking Light, Side Marker Light And License Plate Light Part 5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Taillight, Parking Light, Side Marker Light And License Plate Light Part 6 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair REPLACEMENT OF FRONT SIDE MARKER LIGHT BULB 1. Remove the horn (LH side only). 2. Turn the socket counterclockwise and pull it out and remove the front turn signal light bulb. CAUTION: Do not touch the surface of the bulb with hands or dirty gloves as the bulb may pop after a short time. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Parking Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 Parking Lamp: Electrical Diagrams Taillight, Parking Light, Side Marker Light And License Plate Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 Taillight, Parking Light, Side Marker Light And License Plate Light Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 Taillight, Parking Light, Side Marker Light And License Plate Light Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 Taillight, Parking Light, Side Marker Light And License Plate Light Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 Taillight, Parking Light, Side Marker Light And License Plate Light Part 5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Taillight, Parking Light, Side Marker Light And License Plate Light Part 6 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 6601 Fog Light Relay Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6605 Horn Relay, Theft-Alarm Horn Relay Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 Backup Lamp Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6637 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6638 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6639 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6640 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Brake Light Switch: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 6657 Brake Light Switch: Testing and Inspection STOPLIGHT SWITCH CHECK 1. Connect an ohmmeter between the stoplight switch connector terminals. 2. There should be no continuity between the terminals when the plunger is pushed in as shown. There should be continuity when it is released. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation Fog/Driving Lamp Switch: Description and Operation FOG LIGHT The fog light switch becomes active only when the headlights are at the low-beam mode. Therefore, if the headlights are turned off, the fog lights will also be switched off. When the headlights are turned on during the next key cycle, the fog lights will be off regardless of the fog light switch position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Page 6664 Fog Light Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Hazard Warning Light Switch Continuity Check Hazard Warning Light Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Hazard Warning Light Switch Continuity Check > Page 6669 Hazard Warning Switch: Testing and Inspection Hazard Warning Light Switch Diagnosis The hazard warning lights are controlled by the Simplified Wiring System (SWS). For troubleshooting, refer to, SWS Diagnosis. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 6670 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection Turn Signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Tail Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 Tail Lamp: Electrical Diagrams Taillight, Parking Light, Side Marker Light And License Plate Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 Taillight, Parking Light, Side Marker Light And License Plate Light Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 Taillight, Parking Light, Side Marker Light And License Plate Light Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Taillight, Parking Light, Side Marker Light And License Plate Light Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 Taillight, Parking Light, Side Marker Light And License Plate Light Part 5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 Taillight, Parking Light, Side Marker Light And License Plate Light Part 6 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 6705 Tail Lamp: Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 6706 Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions Trunk Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Trunk Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Trunk Lamp: Electrical Diagrams Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 4 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 5 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 Dome Light, Foot Light, Rear Personal Light And Trunk Light Part 6 Connector/Component Locations: The locations of connectors and components referred to within these diagrams can be found via the connector number at Vehicle Connector Locations. See: Locations/Connector Locations Ground Locations: The locations of grounds referred to within these diagrams can be found via the ground number at Vehicle Ground Locations. See: Locations/Ground Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair Removal And Installation Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair REPLACEMENT OF FRONT TURN SIGNAL LIGHT BULB 1. Remove the horn (LH side only). 2. Turn the socket counterclockwise and pull it out and remove the front turn signal light bulb. CAUTION: Do not touch the surface of the bulb with hands or dirty gloves as the bulb may pop after a short time. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection Turn Signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Vanity Lamp: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Testing and Inspection Defogger Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Testing and Inspection > Page 6782 Heated Glass Element Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Heater Control Assembly and Blower Switch Assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 6790 Power Window Relay: Description and Operation POWER WINDOW RELAY CONTROL OPERATION Power Window Relay Operation If the ignition switch is turned to "ON" position, the power window relay is energized to activate the power windows. Power Window Timer Function When the ignition switch is turned from the "ON" position to "LOCK" (OFF) or "ACC" position, the power windows can be operated for 30 seconds. If any door is opened for the 30 seconds, the power windows will be immobilized at that point. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 6791 Power Window Relay Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Testing and Inspection Defogger Switch Continuity Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Testing and Inspection > Page 6796 Heated Glass Element Switch: Service and Repair REMOVAL AND INSTALLATION Refer to Heater Control Assembly and Blower Switch Assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check Power Window Switch: Testing and Inspection Power Window Main Switch Check Power Window Main Switch Check Power Window Main Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 6801 Power Window Main Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 6802 Power Window Switch: Testing and Inspection Power Window Sub Switch Check Power Window Sub Switch Check Power Window Sub Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 6803 Power Window Switch: Testing and Inspection Power Window Sub Switch Illumination Check Power Window Sub Switch Check Power Window Sub Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Testing and Inspection Power Window Circuit Breaker: Testing and Inspection CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION 1. Pull the power window switch to the UP position to fully close the door window glass, and keep pulling the switch for a further 10 seconds. 2. Release the power window switch from the UP position and immediately press it to the DOWN position. The condition of the circuit breaker is good if the door window glass starts to move downwards within 60 seconds. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Power Window Motor/Window Regulator Assembly Removal And Installation INSTALLATION SERVICE POINTS >>A<< POWER WINDOW MOTOR/WINDOW REGULATOR ASSEMBLY INSTALLATION 1. Power window motor and window regulator assembly installation procedure CAUTION: Do not operate the power window motor until the glass installation is finished. 1. Connect the power window motor to the body-side harness connector, and then turn on the ignition switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 6812 2. Continue to pull the power window switch until the power window motor stops. NOTE: Power window motor stops automatically and the limit switch incorporated in the power motor will be reset. 3. Turn off the ignition switch, and then remove window motor from the body-side harness connector. 4. Align the power window motor drive shaft and the square hole in the drum by the following procedure, while using the guide and the opening in the motor housing as a reference for the installation position. a. Align the square hole with the drive shaft by sliding the glass bracket (glass mounting section) or by turning the drum using a ratchet wrench [with a socket diameter of 12.7 mm (0.50 inch)). b. Turn the drum to position the glass bracket as shown in the illustration. Support the drum and the guide with your hand while turning the drum, otherwise the wires may pull out of the drum. c. If the wires pull out of the drum, reinsert them by following the drum and regulator wire installation procedure. 5. Align the guide and the opening of the motor housing, and slide the guide into the motor housing while holding the guide and drum. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 6813 CAUTION: Make sure that the metal cover is installed securely and do not move, in order to stop the drum from vibrating. If the drum vibrates, the glass may not slide up and down smoothly, or it may fall down. 6. install the metal cover securely to housing. 2. Drum and regulator wire installation procedure 1. Place the drum, guide and regulator on a work bench as shown in the illustration. a. Place the drum so that the square hole is facing upward. b. Place the guide so that the slits are facing upward. c. Place the regulator so that the glass bracket is facing downward. Position the glass bracket so that glass is in the fully-open position. 2. Pass the springs over the wires, and then install the lowering wire to the guide first, followed by the lifting wire. (The lifting wire should be on top of the lowering wire.) Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 6814 3. Use some narrow-gauge wire [approximately 0.5 mm (0.02 inch) diameter] to compress the springs, and then tie the narrow-gauge wire a to the slits in the guide. 4. Insert the end of the lowering wire into the wire hole at the bottom of the drum, and then wrap the bottom so that there is no slackness in the wire. 5. Install the lifting wire to the drum as following: a. Insert the end of the lifting wire into the wire hole at the top of the drum. b. Raise the front of the drum until the drum is vertical, and then position the lifting wire in the groove of the drum. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 6815 c. Return the drum to its original position while holding the wires to make sure that they do not pull out. 6. After installing the power window motor assembly to the power window regulator assembly, cut and remove the wires witch are compressing the springs. 3. Operation check CAUTION: Do not operate the power window regulator assembly before installing the window glass, otherwise the limit switch will be set. Window glass safety mechanism does not operate when the window glass is closed fully at first time. 1. Install the window glass to the power window regulator assembly. 2. Close the window glass completely. NOTE: Closing the window glass completely will finish the adjustment of the limit switch. 3. Check that the limit switch operates correctly. >>B<< DOOR WINDOW GLASS INSTALLATION 1. Temporarily secure the door window glass to the door window regulator. 2. After raising the door window glass as far as it will go, fully secure the door window glass to the power window regulator assembly. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Relay Location Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 6819 Power Window Relay: Description and Operation POWER WINDOW RELAY CONTROL OPERATION Power Window Relay Operation If the ignition switch is turned to "ON" position, the power window relay is energized to activate the power windows. Power Window Timer Function When the ignition switch is turned from the "ON" position to "LOCK" (OFF) or "ACC" position, the power windows can be operated for 30 seconds. If any door is opened for the 30 seconds, the power windows will be immobilized at that point. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 6820 Power Window Relay Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check Power Window Switch: Testing and Inspection Power Window Main Switch Check Power Window Main Switch Check Power Window Main Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 6825 Power Window Main Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 6826 Power Window Switch: Testing and Inspection Power Window Sub Switch Check Power Window Sub Switch Check Power Window Sub Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power Window Main Switch Check > Page 6827 Power Window Switch: Testing and Inspection Power Window Sub Switch Illumination Check Power Window Sub Switch Check Power Window Sub Switch Illumination Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments Front Door Window Glass: Adjustments DOOR WINDOW GLASS ADJUSTMENT Remove the door trim. 1. Remove the waterproof film. 2. Remove the drip line weather-strip. 3. Loosen the bolts and nuts of the following parts. - Delta sash assembly - Power window regulator assembly - Glass carrier plate - Up-stop - Rear lower sash Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments > Page 6832 4. Tighten the power window regulator assembly upper bolts and the glass carrier plate mounting bolts so that the clearances between the weather-strip holder and the window glass as well as between the door panel and the window glass meet the respective standard values. (Sections A - A, B - B, C - C, D - D, E - E.) CAUTION: The right and left adjusting bolts should turned by the same number of threads. 5. Turn the lower adjusting bolts (right and left) of the power window regulator assembly until the clearances between the weather-strip and the window glass meet the respective standard values. (Sections F - F, G - G, H - H.) 6. Press the up-stop against the window glass stop, and then tighten the up-stop nut. 7. Lower the window glass to the extreme position. CAUTION: The adjusting bolts should be turned by the same number of threads. 8. Tighten the adjusting bolts (upper and lower) until the rear lower sash is positioned as shown in the illustration, and then lock the nuts. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments > Page 6833 9. Raise the window glass to the extreme position. 10. Turn the adjusting bolt until the gap between the delta sash assembly and the window glass end meets the shown dimension. 11. Lower the window glass. 12. Lock the adjusting bolt of the delta sash assembly with a nut 13. Tighten the two upper bolts at the delta sash assembly. CAUTION: Ensure that the weather-strip is not wrinkled or out of position. 14. Install the drip line weather-strip to the weather-strip holder. 15. Install the waterproof film. 16. Install the door trim. 17. Check the door window glass alignment according to following procedure. 1. Close the door window glass fully, and close the door until the clearance between the door window glass rear end and the weather-strip reaches 100 mm (3.9 inches). At this time, the distance between the rear end of the belt line molding outer and the quarter panel should be 113.5- 118.5 mm (4.46-4.67 inches). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments > Page 6834 2. The clearance between the glass and the glass catch should be within the range of standard values (a, c, e, g) when the window is fully closed and the door is closed gently. Standard value a. : 2.9 ± 1.0 mm (0.11 ± 0.04 inch) c. : 4.5 ± 1.0 mm (0.18 ± 0.04 inch) e. : 3.4 mm (0.13 inch) g. : 10.7 ± 1.0 mm (0.42 ± 0.04 inch) NOTE: If the clearance is too small the glass catch will move above the glass when the door is closed. If the clearance is too large, wind noise may be generated at high vehicle speed because the glass catch is not hooked onto the glass. 3. The amount of catch of the door catch on the door glass and the weather-strip should be at the standard values (b, d, f) when the window is closed fully and then the door is closed. Standard value b. : 2.7 ± 1.0 mm (0.11 ± 0.04 inch) d. : 2.7 ± 1.0 mm (0.11 ± 0.04 inch) f. : 2.4 ± 1.0 mm (0.09 ± 0.04 inch) 4. The door glass should slide smoothly over its full range of movement when the door is closed. 5. The glass catch and the weather-strip should be parallel with the door glass and the two up-stops should touch simultaneously when the glass is fully closed. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Adjustments > Page 6835 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 23-020-03 > Aug > 03 > Body - Door Glass Rubbing/Screeching Sound Window Track: Customer Interest Body - Door Glass Rubbing/Screeching Sound NUMBER: 23-020-03 GROUP: Body DATE: August 8, 2003 SUBJECT: Door Glass Rub/Screech/Squeak Sound OVERVIEW: This bulletin involves adjusting the lower sash in the door that is emitting the rub/screech/squeak sound. MODELS: 2003 ST Sebring Coupe/Stratus Coupe SYMPTOM/CONDITION: The vehicle may exhibit a rub/screech/squeak sound when the window is raised from the down position in one or both doors. DIAGNOSIS: Lower the glass completely in the each door. Raise the glass and listen for a rub/screech/squeak sound. If the Symptom/Condition is present, perform the Repair Procedure in the affected door. REPAIR PROCEDURE: 1. Remove the appropriate door trim panel. Refer to the service information available in TechCONNECT or the Sebring/Stratus Coupe Service Manual, Volume 4, publication number 81-270-03031D, page 23C-40. 2. Loosen the lower sash upper and lower nuts (Fig. 1). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 23-020-03 > Aug > 03 > Body - Door Glass Rubbing/Screeching Sound > Page 6844 3. Right hand door, proceed to step 4. Left hand door, proceed to step 5. 4. Right hand door: a. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 6. 5. Left hand door: a. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 6. 6. Lower the glass completely in the affected door. Raise the glass and listen for a rub/screech/squeak sound. 7. If the sound is no longer present, proceed to step 14. If sound is present, proceed to next step. 8. Remove the sash. 9. Inspect the lower part of the sash for a tang that is contacting the glass. Fold the tang inward, clamping onto the vinyl. 10. Install the sash and loosely install the upper and lower nuts (Fig. 1) 11. Right hand door, proceed to step 12. Left hand door, proceed to step 13. 12. Right hand door: a. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 14. 13. Left hand door: a. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 14. 14. Install the trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 23-020-03 > Aug > 03 > Body - Door Glass Rubbing/Screeching Sound > Page 6845 FAILURE CODE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-020-03 > Aug > 03 > Body - Door Glass Rubbing/Screeching Sound Window Track: All Technical Service Bulletins Body - Door Glass Rubbing/Screeching Sound NUMBER: 23-020-03 GROUP: Body DATE: August 8, 2003 SUBJECT: Door Glass Rub/Screech/Squeak Sound OVERVIEW: This bulletin involves adjusting the lower sash in the door that is emitting the rub/screech/squeak sound. MODELS: 2003 ST Sebring Coupe/Stratus Coupe SYMPTOM/CONDITION: The vehicle may exhibit a rub/screech/squeak sound when the window is raised from the down position in one or both doors. DIAGNOSIS: Lower the glass completely in the each door. Raise the glass and listen for a rub/screech/squeak sound. If the Symptom/Condition is present, perform the Repair Procedure in the affected door. REPAIR PROCEDURE: 1. Remove the appropriate door trim panel. Refer to the service information available in TechCONNECT or the Sebring/Stratus Coupe Service Manual, Volume 4, publication number 81-270-03031D, page 23C-40. 2. Loosen the lower sash upper and lower nuts (Fig. 1). Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-020-03 > Aug > 03 > Body - Door Glass Rubbing/Screeching Sound > Page 6851 3. Right hand door, proceed to step 4. Left hand door, proceed to step 5. 4. Right hand door: a. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 6. 5. Left hand door: a. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 6. 6. Lower the glass completely in the affected door. Raise the glass and listen for a rub/screech/squeak sound. 7. If the sound is no longer present, proceed to step 14. If sound is present, proceed to next step. 8. Remove the sash. 9. Inspect the lower part of the sash for a tang that is contacting the glass. Fold the tang inward, clamping onto the vinyl. 10. Install the sash and loosely install the upper and lower nuts (Fig. 1) 11. Right hand door, proceed to step 12. Left hand door, proceed to step 13. 12. Right hand door: a. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 14. 13. Left hand door: a. Slide the upper nut forward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). b. Slide the lower nut rearward and tighten to 10 - 15 Nm (88 - 133 in. lbs.). c. Proceed to step 14. 14. Install the trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-020-03 > Aug > 03 > Body - Door Glass Rubbing/Screeching Sound > Page 6852 FAILURE CODE: Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed Compact Disc Player (CD): All Technical Service Bulletins Audio System - 'CD ERR' Message Displayed NUMBER: 08-028-03 GROUP: Electrical DATE: September 19, 2003 SUBJECT: Radio CD ERR Message MODELS: 2002 - 2003 (AN) Dakota 2002 - 2003 (DN) Durango 2002 - 2004 (DR) Ram Truck 2004 (HB) Durango 2002 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2002 - 2004 (PL) Neon 2002 - 2004 (PT) Chrysler PT Crusier 2002 - 2004 (RG) Chrysler Voyager (International Markets) 2002 - 2004 (RS) Town & Country/Voyager/Caravan 2002 - 2004 (TJ) Wrangler 2002 - 2004 (WG) Grand Cherokee (International Markets) 2002 - 2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper NOTE: This bulletin applies to vehicles equipped radio sales codes RAZ, RAD, RBK, RBP, RAH, REF, RAQ and RAR. DISCUSSION: Here are some common problems of why a CD ERR may occur: 1. CD's are not always compatible with a CD player. Usually these are homemade CD's (write/re-write), however some low quality CD's may not be compatible. 2. Scratches on a CD. Most of the time a CD will skip when the player sees a scratch but in some cases the scratches are so severe that a CD ERR will occur. 3. Finger prints on the CD. The oil from finger prints may prevent the Optical Pickup from reading the disc. 4. Foreign materials on a CD such as; carpet fibers, liquid spills, candy, etc. may prevent the Optical Pickup from reading a disc. 5. CD's warped from being in extreme heat. If a CD is warped too much then it should not fit into the CD slot, thus preventing insertion. However, some CD's that are not perfectly flat may be inserted with little effort. The CD player may or may not read these CD's. 6. In climate condition where the CD player is exposed to frigid temperatures or high humidity condensation may form on the Optical Pickup. This condition will correct itself once the vehicle's cabin temperature stabilizes. What a dealer should do before removing a CD player for repair. 1. Find out as much information as possible about the failure from the customer. a. Does the CD player work at all or is it intermittent? b. Does the failure occur when using certain CD's? c. Are the CD's homemade or inexpensive CD's? d. Does the failure occur during the first few minutes when the temperature is either frigid or hot and humid? e. Will the customer make his CD's available to you for testing and inspection? Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed > Page 6858 2. Inspect the customers CD's. a. Look for scratches, finger prints, foreign materials. . Look for warped CD's. 3. Test the CD player with a known good CD. 4. Test the customer's CD's in a like unit. Do not test in a different type of CD player because CD players vary in performance from manufacturer to manufacturer and model to model. 5. If the condition can be verified and it is the CD player's fault, replace the unit. Caution for customers: 1. Do not use CD's with labels. CD players operate at a high temperature which may cause the label to peel up or come off. This may prevent the CD from ejecting or if label falls into the mechanism it may cause the mechanism to jam. 2. When CD's are not in use, store them in a method to prevent them from getting damaged. 3. Clean the CD's before using them. To clean a CD, use rubbing alcohol and a soft cloth. Wipe the CD from the center to the outboard edge, not a circular motion. 4. Do not try to remove a jammed CD. POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 08-028-03 > Sep > 03 > Audio System - 'CD ERR' Message Displayed > Page 6864 2. Inspect the customers CD's. a. Look for scratches, finger prints, foreign materials. . Look for warped CD's. 3. Test the CD player with a known good CD. 4. Test the customer's CD's in a like unit. Do not test in a different type of CD player because CD players vary in performance from manufacturer to manufacturer and model to model. 5. If the condition can be verified and it is the CD player's fault, replace the unit. Caution for customers: 1. Do not use CD's with labels. CD players operate at a high temperature which may cause the label to peel up or come off. This may prevent the CD from ejecting or if label falls into the mechanism it may cause the mechanism to jam. 2. When CD's are not in use, store them in a method to prevent them from getting damaged. 3. Clean the CD's before using them. To clean a CD, use rubbing alcohol and a soft cloth. Wipe the CD from the center to the outboard edge, not a circular motion. 4. Do not try to remove a jammed CD. POLICY: Information Only Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair Windshield: Service and Repair Removal and Installation Windshield Removal Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 6868 1. To protect the body (paint surface), apply cloth tape to all body areas around the installed. 2. Using piano wire 1. Using a sharp-point drill, make a hole in the windshield adhesive. 2. Pass the piano wire from the inside of the vehicle through the hole. 3. Using a sharp-point drill, make a hole in the windshield adhesive. 4. Pass the piano wire from the inside of the vehicle through. Caution: Do not let the piano wire touch the edge of the windshield. 5. Pull the piano wire alternately from the inside and outside along the windshield to cut the adhesive. 3. Using glass adhesive knife 1. Get glass adhesive knife. Caution: Putting glass adhesive knife too deeply into windshield adhesive may damage windshield. 2. Keep glass adhesive knife at right angles with the windshield edge, and put the blade at the windshield edge and surface. Then cut away adhesive along the windshield edge. 4. Make mating marks on the windshield and body. 5. Use special tool MB990480 to remove the windshield. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 6869 Caution: - Be careful not to remove more adhesive than is necessary. - Be careful also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with repair paint or anti-rust agent. 6. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm (0.08 inch) around the entire circumference of the body flange. 7. Finish the flange surfaces so that they are smooth. Caution: Allow the cleaned area to dry for at least three minutes. Do not touch any surface that has been cleaned. 8. When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with 3M AAD Part number 8906 or equivalent. 9. Clean the body side in the same way. Installation Service Point Windshield Upper Molding/Glass Stopper/Windshield Spacer/Spacer/ Windshield Installation 1. When replacing the windshield, temporarily set the windshield against the body, and place a mating mark on the windshield and body. 2. Use 3M AAD Part number 8906 or equivalent to de grease the inside and outside of the windshield and the body flanges. Caution: - The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference. However, a too thick application will weaken the adhesive. - Do not touch the coated surface. 3. Soak a sponge in the primer, and apply evenly to the windshield and the body in the specified places. 4. Apply the primer, and then let it dry for 3 to 30 minutes, depending on the ambient temperature and humidity. 5. Install the windshield upper molding to the windshield. 6. Install the glass stopper to the windshield. 7. Place the window spacer to the windshield so that it inclines toward the windshield and its right and ;eft clearances are equal. Then install the spacer firmly so that it is firmly anchored. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Page 6870 8. Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer. Note: Cut the tip of the sealant gun nozzle into a V shape to simplify adhesive application. 9. Align the mating marks on the windshield and the body, and lightly press the windshield evenly so that it adheres completely. 10. Use a spatula or similar tool to remove any excessive adhesive. Clean the surface with 3M AAD Part number 8906 or equivalent. Avoid moving the vehicle until the adhesive sets. Caution: - Do not move the vehicle unless absolutely necessary. - When testing for water leakage, do not pinch the end of the hose to spray water. 11. Wait 30 minutes or more, and then test for water leakage. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Windshield Washer Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 Wiper Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 Wiper Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Testing and Inspection Washer Fluid Level Switch: Testing and Inspection WASHER FLUID LEVEL SWITCH CHECK Connect a circuit tester to the connector of the level sensor as shown. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test Windshield Washer Switch: Testing and Inspection Windshield Wiper/Washer Switch Test WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK Check continuity between the switch terminals. WINDSHIELD INTERMITTENT WIPER VOLUME CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test > Page 6956 Check that the resistance varies between 0 and 1 kilo ohm when the windshield intermittent volume is turned from FAST to SLOW by measuring resistance between connector terminals 27 and 28 at the column switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test > Page 6957 Turn-signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems Turn-signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems > Page 6962 Wiper Switch: Testing and Inspection Windshield Wipers and Washers WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK Check continuity between the switch terminals. WINDSHIELD INTERMITTENT WIPER VOLUME CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems > Page 6963 Check that the resistance varies between 0 and 1 kilo ohm when the windshield intermittent volume is turned from FAST to SLOW by measuring resistance between connector terminals 27 and 28 at the column switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Testing and Inspection Washer Fluid Level Switch: Testing and Inspection WASHER FLUID LEVEL SWITCH CHECK Connect a circuit tester to the connector of the level sensor as shown. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Testing and Inspection Windshield Washer Motor: Testing and Inspection WASHER MOTOR CHECK 1. With the washer motor installed to the washer tank, fill the washer tank with water 2. Check that water is sprayed out strongly when battery voltage is applied to terminal (1) and terminal (2) is grounded. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 Windshield Washer Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test Windshield Washer Switch: Testing and Inspection Windshield Wiper/Washer Switch Test WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK Check continuity between the switch terminals. WINDSHIELD INTERMITTENT WIPER VOLUME CHECK Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test > Page 6999 Check that the resistance varies between 0 and 1 kilo ohm when the windshield intermittent volume is turned from FAST to SLOW by measuring resistance between connector terminals 27 and 28 at the column switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Windshield Wiper/Washer Switch Test > Page 7000 Turn-signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Wiper Control Module: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 Wiper Motor: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7064 Wiper Motor: Testing and Inspection WIPER MOTOR CHECK Check the wiper motor after disconnecting the wiring harness connector, with the wiper motor remaining installed to the body. Wiper Motor at Low-Speed and High-Speed Operation Connect the battery to the wiper motor as shown in the illustration, and then check the operation of the wiper motor at low speed and at high speed. Wiper Motor at Stop Position Operation 1. Connect the wiper motor connector to the battery as shown by (A) in the illustration. 2. Run the windshield wiper motor at low speed. When the connector is disconnected from the battery while the motor is running, the motor should stop. 3. Connect the terminals of the windshield wiper motor connectors as shown by (B) in the illustration. 4. Check to see that the windshield wiper motor runs at low speed and then stops at the automatic stop position. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions How To Read Circuit Diagrams - Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 How To Read Circuit Diagrams - Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Connector/Grounding Indications Part 1 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 Connector/Grounding Indications Part 2 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 Connector/Grounding Indications Part 3 Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 Symbols (Except Connector And Grounding) Wire Color Codes Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 How To Read Configuration Diagrams Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 How To Read Splice Locations Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 Wiper Relay: Diagnostic Aids Harness Connector Inspection CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: - MB991219: Test Harness Set - MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at terminals of waterproof connectors. CAUTION: Never backprobe a waterproof connector. Backprobing this type of a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit is to be checked in the closed state, use a special tool such as MD998459. CAUTION: Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (such as MB991219). CAUTION: Do not contact more than one terminal with the probe at the same time. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector. CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuits can be done in the following manner. COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it. 2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there. 3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal. 3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom. RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7079 2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal. 3. Press the contact point of the female terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom. INJECTOR CONNECTOR 1. Remove the waterproof cap. 2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal. CAUTION: Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point of the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 Cable and Wires Check 1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion by battery electrolyte, etc. 3. Check terminals and wires for open circuit or frayed wires. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10. Check that the harness between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement. Battery Handling WARNING: Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last. Cautions In Event of Blown Fuse When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. Checking Fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. Checking Relays NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF). 2. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. When a normally closed relay as illustrated here is checked, there should be continuity between terminals 1 and 2 and between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage is applied between terminals 1 and 2. Checking Switches In a circuit diagram, a switch is shown in the normal condition. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise. 2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below. General Electrical System Check GENERAL ELECTRICAL SYSTEM CHECK A circuit consists of the power supply, switch, relay, load, ground, etc. "there are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below apply only to circuits similar to the illustration. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 1. VOLTAGE CHECK 1. Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. 2. Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. 3. Then, connect the test tight or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. 4. The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to identify the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES: Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 NO: Go to Step 2. STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES: Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO: Short-circuit exists between the connector and the illumination light. Repair the harness between the switch and the connector. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 3. CONTINUITY CHECK 1. When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the self-powered test light should illuminate or the ohmmeter should read 0 ohm. 2. When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the self-powered test light should come on or the ohmmeter should read 0 ohm. Information For Diagnosis INFORMATION FOR DIAGNOSIS This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions. 3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component reacts. 4. Troubleshooting hints include numerous examples of problems which might occur. Most of the problems can be traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant sections that includes details of these components. Inspection 1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when relay covers are pushed down. 2. Simple checks For example, if a headlight does not come on, a faulty fuse or poor grounding is suspected. Replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly. Inspection Instruments For inspection, use the following instruments: 1. Test lights A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits. CAUTION: Never use a test light for checking ECU-related circuits or ECUs. 2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding. 3. Jumper wire A jumper wire is used to close an open circuit. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 CAUTION: Never use a jumper wire to connect a power supply directly to a load. 4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop upstream and downstream of a component. 5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or a coil. If the measuring range has been changed, the zero point must be adjusted before measurement. Troubleshooting Steps HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting. Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems Turn-signal And Lighting Switch Check Dodge Stratus Coupe Workshop Manual (L4-2.4L VIN G (2003)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Turn Signal and Hazard Warning Systems > Page 7094 Wiper Switch: Testing and Inspection Windshield Wipers and Washers WINDSHIELD WIPER AND WINDSHIELD WASHER SWITCH CHECK Check continuity between the switch terminals. WINDSHIELD INTERMITTENT WIPER VOLUME CHECK