Chrysler Town, Dodge Caravan. Manual - part 295

module. The IPM cover is unlatched and opened or
removed to access the fuses or relays. Internal con-
nections of all of the power distribution center cir-
cuits is accomplished by a combination of bus bars
and a printed circuit board. Refer to the Wiring sec-
tion of the service manual for complete IPM circuit
schematics.

REMOVAL

(1) Disconnect the negative and positive battery

cables.

(2) Remove the battery thermal guard from the

vehicle. Refer to the Battery section for the proce-
dure.

(3) Remove the battery from the vehicle. Refer to

the Battery section for the procedure.

(4) Using a flat-bladed screwdriver, twist the Inte-

grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 3).

(5) Rotate the IPM counter-clockwise to access and

disconnect the various electrical connectors (Fig. 4).

(6) Free the IPM from its mounting bracket by

removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.

INSTALLATION

(1) Snap the left side of the Integrated Power Mod-

ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors. Care must be
taken that the Connector Positive Assurance (CPA)

on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).

NOTE: IPM electrical connectors are color coded to
ease location reference.

(2) Being certain no wires are stressed or pinched,

rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.

(3) Install the battery in the vehicle. Refer to the

Battery section for the procedure.

(4) Install the battery thermal guard in the vehi-

cle. Refer to the Battery section for the procedure.

(5) Connect the negative and positive battery

cables.

(6) Using a diagnostic scan tool, check for any

stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.

IOD FUSE

DESCRIPTION

All vehicles are equipped with an Ignition-Off

Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) when
the vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.

Fig. 3 RELEASING INTEGRATED POWER MODULE

FROM ITS MOUNTING BRACKET

Fig. 4 DISCONNECTING IPM

1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER

8W - 97 - 4

8W-97 POWER DISTRIBUTION SYSTEM

INTEGRATED POWER MODULE (Continued)

The IPM has a molded plastic cover that can be

removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
tion. The IOD fuse is a 20 ampere blade-type mini
fuse and, when removed, it is stored in a fuse cavity
adjacent to the washer fuse within the IPM.

OPERATION

The term ignition-off draw identifies a normal con-

dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.

The IOD fuse is removed from the IPM fuse cavity

when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.

The IOD fuse can be used by the vehicle owner as

a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery System for additional service information.

REMOVAL

(1) Turn the ignition switch to the Off position.

(2) Unlatch and open the cover of the intelligent

power module.

(3) Remove

the

IOD

fuse

from

fuse

location

marked IOD of the Integrated Power Module (IPM).

(4) Store the removed IOD fuse by installing it in

the unused fuse storage marked SPARE of the IPM.

(5) Close and latch the IPM.

INSTALLATION

(1) Be certain the ignition switch is in the Off posi-

tion.

(2) Unlatch and open the cover of the Integrated

Power Module (IPM).

(3) Use a thumb to press the IOD fuse firmly down

into IPM fuse cavity marked IOD.

(4) Close and latch the IPM cover.

POWER OUTLET

DESCRIPTION

Accessory power outlets are standard equipment on

this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.

The power outlet receptacle unit and the power

outlet plugs are each available for service replace-
ment.

OPERATION

The power outlet base or receptacle shell is con-

nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.

The power outlet located in the center console

receives battery voltage all the time when positioned
between the front seats and key-on voltage when
positioned between the rear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.

8W-97 POWER DISTRIBUTION SYSTEM

8W - 97 - 5

IOD FUSE (Continued)

DIAGNOSIS AND TESTING

DIAGNOSIS & TESTING - POWER OUTLET

For complete circuit diagrams, refer to Cigar

Lighter/Power Outlet in Wiring Diagrams.

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS

SERVICE.

FAILURE

TAKE

THE

PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.

(1) Check the fused B(+) fuse in the Integrated

Power Module (IPM). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.

(2) Check for battery voltage at the fused B(+) fuse

in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.

(3) Open the power outlet door. Check for continuity

between the inside circumference of the power outlet
receptacle and a good ground. There should be continu-
ity. If OK, go to Step 4. If not OK, go to Step 5.

(4) Check for battery voltage at the insulated con-

tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.

(5) Disconnect and isolate the battery negative

cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.

(6) Connect the battery negative cable. Check for

battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.

REMOVAL

(1) Disconnect and isolate the battery negative cable.
(2) Look inside and note position of the retaining

bosses (Fig. 5).

(3) Using external snap ring pliers with 90 degree

tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.

(4) Pull out the base through mounting ring by

gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 6).

(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-

nect wire.

INSTALLATION

(1) Position the mounting ring on the instrument

panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o’clock position to the key in the instrument panel.
Install the ring.

(2) Connect the wires to the base. Orientate the

base alignment rib at the 11 o’clock position to mate
the groove in the mounting ring to the base.

(3) Push the base into the bezel until it locks in place.
(4) Check operation of outlet or element and

install the 12 volt outlet cap.

Fig. 5 Outlet Base Removal

1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING

Fig. 6 Tool For Outlet Removal

1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)

8W - 97 - 6

8W-97 POWER DISTRIBUTION SYSTEM

POWER OUTLET (Continued)

ENGINE